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The energy you need Installation and main- tenance instructions Ultimate 3 30c 35c GB, IE

Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

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Page 1: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

The energy you need

Installation and main-tenance instructionsUltimate 3

30c

35c

GB IE

Contents

2 Installation and maintenance instructions Ultimate 3 0020239566_01

Contents

1 Safety 4

11 Action-related warnings 4

12 Risk caused by inadequate qualifications 4

13 Intended use 4

14 General safety information 4

15 Regulations (directives laws standards) 6

2 Notes on the documentation 7

21 Observing other applicable documents 7

22 Storing documents 7

23 Applicability of the instructions 7

3 Product description 7

31 Compartment Ventilation 7

32 Serial number 7

33 Information on the identification plate 7

34 Functional elements Combination unit 8

35 CE label 8

4 Set-up 8

41 Transporting the unit 8

42 Unpacking the product 8

43 Checking the scope of delivery 8

44 Dimensions 9

45 Minimum clearances 9

46 Clearance from combustible components 9

47 Using the installation template 9

48 Wall-mounting the product 9

49 Removinginstalling the front casing 10

410 Removinginstalling the side section 10

5 Installation 11

51 Checking the gas meter 11

52 Gas and water connections 11

53 Connecting the drain line for the expansionrelief valve 12

54 Connecting the condensate drain pipework 12

55 Connecting the drain cock 12

56 Electrical installation 12

6 Operation 14

61 Using diagnostics codes 14

62 Displaying the status codes 14

63 Using check programmes 15

7 Start-up 15

71 Carrying out the initial start-up 15

72 Checking the factory setting 15

73 Checking and treating the heating waterfillingand supplementary water 15

74 Avoiding danger arising from insufficient waterpressure 16

75 Switching on the product 17

76 Filling and purging the heating installation 17

77 Filling the condensate siphon 17

78 Filling the hot water circuit 17

79 Checking and adjusting the gas ratio setting 17

710 Checking leak-tightness 19

8 Adapting the unit to the heatinginstallation 20

81 Burner anti-cycling time 20

82 Setting the pump output 20

83 Setting the bypass 20

9 Adjusting the hot water temperature 21

91 Setting the hot water temperature 21

10 Handing the product over to the operator 21

11 Inspection and maintenance 21

111 Observing inspection and maintenanceintervals 21

112 Procuring spare parts 21

113 Checking the CO₂ content 21

114 Setting the CO₂ content 22

115 Removing the gas-air mixture unit 22

116 Cleaning the heat exchanger 23

117 Checking the burner 23

118 Checking the ignition electrode 23

119 Cleaning the condensate tray 23

1110 Cleaning the condensate siphon 24

1111 Cleaning the filter in the cold water inlet 24

1112 Cleaning the heating filter 25

1113 Installing the gas-air mixture unit 25

1114 Draining the product 25

1115 Checking the pre-charge pressure of theexpansion vessel 25

1116 Completing inspection and maintenance work 25

12 Troubleshooting 25

121 Rectifying faults 25

122 Calling up the fault memory 25

123 Deleting the fault memory 25

124 Resetting parameters to factory settings 26

125 Preparing the repair work 26

126 Replacing defective components 26

127 Completing repair work 29

13 Decommissioning the product 29

14 Customer service 29

Appendix 30

A Check programmes ndash Overview 30

B Overview of diagnostics codes 30

C Status codes ndash Overview 34

D Overview of fault codes 35

E Connection diagram Combination unit 37

F Connection diagram Combination unit (35kW) 38

G Inspection and maintenance work ndashOverview 39

H Opening in the airflue pipe 40

H1 Positioning of the opening of a fan-supportedflue gas pipe 40

H2 Horizontal terminal positioning 41

I Commissioning Checklist 42

J Combustion chart 45

K Lengths of the airflue pipe 46

Contents

0020239566_01 Ultimate 3 Installation and maintenance instructions 3

L Technical data 46

Index 49

1 Safety

4 Installation and maintenance instructions Ultimate 3 0020239566_01

1 Safety

11 Action-related warnings

Classification of action-related warningsThe action-related warnings are classified inaccordance with the severity of the possibledanger using the following warning signs andsignal words

Warning symbols and signal wordsDangerImminent danger to life or risk ofsevere personal injury

DangerRisk of death from electric shock

WarningRisk of minor personal injury

CautionRisk of material or environmentaldamage

12 Risk caused by inadequatequalifications

The following work must only be carried outby competent persons who are sufficientlyqualified to do so

ndash Installationndash Disassemblyndash Installationndash Start-upndash Maintenancendash Repairndash Decommissioning

Observe all instructions that are includedwith the product

Proceed in accordance with the currentstate of technology

Observe all applicable directives stand-ards laws and other regulations

13 Intended use

There is a risk of injury or death to the user orothers or of damage to the product and otherproperty in the event of improper use or usefor which it is not intended

The product is intended as a heat generatorfor closed heating installations and for hotwater generation

Depending on the gas-fired boiler type theproducts referred to in these instructionsmust only be installed and operated in con-junction with the airflue pipe accessories lis-ted in the other applicable documents

Intended use includes the following

ndash observance of accompanying operatinginstallation and servicing instructions forthe product and any other system compon-ents

ndash installing and fitting the product in accord-ance with the product and system approval

ndash compliance with all inspection and main-tenance conditions listed in the instruc-tions

Intended use also covers installation in ac-cordance with the IP class

Any other use that is not specified in theseinstructions or use beyond that specified inthis document shall be considered improperuse Any direct commercial or industrial useis also deemed to be improper

Caution

Improper use of any kind is prohibited

14 General safety information

141 Risk of death from escaping gas

What to do if you smell gas in the building

Avoid rooms that smell of gas If possible open doors and windows fully

and ensure adequate ventilation Do not use naked flames (eg lighters

matches) Do not smoke Do not use any electrical switches mains

plugs doorbells telephones or other com-munication systems in the building

If it is safe to do so close the emergencycontrol valve or the main isolator

Safety 1

0020239566_01 Ultimate 3 Installation and maintenance instructions 5

If possible close the gas isolator cock onthe product

Warn other occupants in the building byyelling or banging on doors or walls

Leave the building immediately and ensurethat others do not enter the building

Notify the gas supply company or the Na-tional Grid +44 (0) 800 111999 by tele-phone once you are outside of the build-ing

142 Risk of death from escaping fluegas

If you operate the product with an empty con-densate siphon flue gas may escape into theroom air

In order to operate the product ensure thatthe condensate siphon is always full

143 Risk of death due to blocked orleaking flue gas routes

Installation errors damage tampering unau-thorised installation sites or similar can causeflue gas to escape and result in a risk of pois-oning

What to do if you smell flue gas in the prop-erty

Open all accessible doors and windowsfully to provide ventilation

Switch off the product Check the flue gas routes in the product

and the flue gas diversions

144 Risk of death due to explosive andflammable materials

Do not use or store explosive or flammablematerials (eg petrol paper paint) in theinstallation room of the product

145 Risk of death from electric shock

There is a risk of death from electric shock ifyou touch live components

Before commencing work on the product

Unplug the mains plug Or disconnect the product from the power

supply by switching off all power supplies(electrical partition with a contact openingof at least 3 mm eg fuse or line protec-tion switch)

Secure against being switched back onagain

Wait for at least 3 minutes until the con-densers have discharged

146 Risk of death due to lack of safetydevices

The schematic drawings included in this doc-ument do not show all safety devices re-quired for correct installation

Install the necessary safety devices in thesystem

Observe the applicable national and inter-national laws standards and guidelines

147 Risk of poisoning and burns causedby escaping hot flue gases

Only operate the product if the airflue pipehas been completely installed

With the exception of short periods fortesting purposes only operate the productwhen the front casing is installed andclosed

148 Risk of being burned or scalded byhot components

Only carry out work on these componentsonce they have cooled down

149 Risk of injury during transport dueto a high product weight

Make sure that the product is transportedby at least two people

1410 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the fluegas guiding

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similar

1 Safety

6 Installation and maintenance instructions Ultimate 3 0020239566_01

locations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the airfluepipe

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1412 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1413 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenscrew connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020239566_01 Ultimate 3 Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Applicability of the instructions

These instructions apply only to

Product article number

Article number Gas Council Num-ber

ULTIMATE 3 30c 0010021404 47-019-55

ULTIMATE 3 35c 0010021405 47-019-57

These products are only designed for natural gas systems

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Serial number

2

3

1

The serial number is located on the identification plate (1)and in the short operating instructions (2) (rarr Page 7)

Stickers showing the serial number are on the back of theelectronics box (3)

33 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

The identification plate keeps record of the country in whichthe product is to be installed

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

For quality control purposes 5th and 6thdigits = week of production

For identification purposes 7th to 16thdigits = product article number

For quality control purposes 17th to 20thdigits = place of manufacture

Ultimate 3 Product designation

XX Gxx ndash xx mbar(x kPa)

Gas group and gas connection pressureas set at the factory

Cat Approved gas category

Condensing techno-logy

Efficiency of the boiler in accordancewith directive 9242EWG

Type Xx3(x) Approved flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

GC no Gas council number

4 Set-up

8 Installation and maintenance instructions Ultimate 3 0020239566_01

34 Functional elements Combination unit

15

131211

9

10

8

6

5

7

4

3

2

1

17

16

19 18

14

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Pressure gauge

5 Condensate siphon

6 Flue gas pipe

7 Pressure sensor

8 Flue gas measuringstub pipe

9 Ignition transformer

10 Gas valve

11 Air intake pipe

12 Ignition electrode

13 Fan

14 Primary heat exchanger

15 Heating expansionvessel

16 Flow rate sensor

17 Heating pump

18 Bypass

19 Diverter valve

35 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend your legs at the knee

Hold the load as close as possible to your body

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete

Quantity Description

1 Heat generator

1

Bag with accessories

ndash Bag with seals

ndash Condensate drain hose

ndash Drain spigot of the expansion relief valve

ndash Hanging bracket

ndash Bag containing the hydraulic connections

1 Enclosed documentation

Set-up 4

0020239566_01 Ultimate 3 Installation and maintenance instructions 9

44 Dimensions

A

C

B

D

Dimensions

A B C D

740 mm 130 mm 300 mm 418 mm

45 Minimum clearances

C C D

AB

Minimum clearances

A B C D

ge 150 mm ge 150 mm ge 0 mm

Note

ge 50 mm (re-quired clear-ance for re-moving theside section)

ge 600 mm

Note

ge 5 mm (forcabinet-typecasing)

46 Clearance from combustible components

It is not necessary to maintain a specified clearance betweenthe product and components made of combustible materials

47 Using the installation template

Use the installation template to ascertain the locations atwhich you need to drill holes and make breakthroughs

48 Wall-mounting the product

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the weight of the product under operatingconditions (operational weight)

2 Wall-mount the product as described using the adaptedfixing material provided on-site

4 Set-up

10 Installation and maintenance instructions Ultimate 3 0020239566_01

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial may be used for the wall

A

B

Wall-mount the product as described

Conditions The load-bearing capacity of the wall is not sufficient

Ensure that wall-mounting apparatus on-site has a suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

49 Removinginstalling the front casing

491 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

492 Fitting the front panel

Refit the components in the reverse order

410 Removinginstalling the side section

4101 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least 50mm) you can remove the side section to facilitatemaintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 2: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Contents

2 Installation and maintenance instructions Ultimate 3 0020239566_01

Contents

1 Safety 4

11 Action-related warnings 4

12 Risk caused by inadequate qualifications 4

13 Intended use 4

14 General safety information 4

15 Regulations (directives laws standards) 6

2 Notes on the documentation 7

21 Observing other applicable documents 7

22 Storing documents 7

23 Applicability of the instructions 7

3 Product description 7

31 Compartment Ventilation 7

32 Serial number 7

33 Information on the identification plate 7

34 Functional elements Combination unit 8

35 CE label 8

4 Set-up 8

41 Transporting the unit 8

42 Unpacking the product 8

43 Checking the scope of delivery 8

44 Dimensions 9

45 Minimum clearances 9

46 Clearance from combustible components 9

47 Using the installation template 9

48 Wall-mounting the product 9

49 Removinginstalling the front casing 10

410 Removinginstalling the side section 10

5 Installation 11

51 Checking the gas meter 11

52 Gas and water connections 11

53 Connecting the drain line for the expansionrelief valve 12

54 Connecting the condensate drain pipework 12

55 Connecting the drain cock 12

56 Electrical installation 12

6 Operation 14

61 Using diagnostics codes 14

62 Displaying the status codes 14

63 Using check programmes 15

7 Start-up 15

71 Carrying out the initial start-up 15

72 Checking the factory setting 15

73 Checking and treating the heating waterfillingand supplementary water 15

74 Avoiding danger arising from insufficient waterpressure 16

75 Switching on the product 17

76 Filling and purging the heating installation 17

77 Filling the condensate siphon 17

78 Filling the hot water circuit 17

79 Checking and adjusting the gas ratio setting 17

710 Checking leak-tightness 19

8 Adapting the unit to the heatinginstallation 20

81 Burner anti-cycling time 20

82 Setting the pump output 20

83 Setting the bypass 20

9 Adjusting the hot water temperature 21

91 Setting the hot water temperature 21

10 Handing the product over to the operator 21

11 Inspection and maintenance 21

111 Observing inspection and maintenanceintervals 21

112 Procuring spare parts 21

113 Checking the CO₂ content 21

114 Setting the CO₂ content 22

115 Removing the gas-air mixture unit 22

116 Cleaning the heat exchanger 23

117 Checking the burner 23

118 Checking the ignition electrode 23

119 Cleaning the condensate tray 23

1110 Cleaning the condensate siphon 24

1111 Cleaning the filter in the cold water inlet 24

1112 Cleaning the heating filter 25

1113 Installing the gas-air mixture unit 25

1114 Draining the product 25

1115 Checking the pre-charge pressure of theexpansion vessel 25

1116 Completing inspection and maintenance work 25

12 Troubleshooting 25

121 Rectifying faults 25

122 Calling up the fault memory 25

123 Deleting the fault memory 25

124 Resetting parameters to factory settings 26

125 Preparing the repair work 26

126 Replacing defective components 26

127 Completing repair work 29

13 Decommissioning the product 29

14 Customer service 29

Appendix 30

A Check programmes ndash Overview 30

B Overview of diagnostics codes 30

C Status codes ndash Overview 34

D Overview of fault codes 35

E Connection diagram Combination unit 37

F Connection diagram Combination unit (35kW) 38

G Inspection and maintenance work ndashOverview 39

H Opening in the airflue pipe 40

H1 Positioning of the opening of a fan-supportedflue gas pipe 40

H2 Horizontal terminal positioning 41

I Commissioning Checklist 42

J Combustion chart 45

K Lengths of the airflue pipe 46

Contents

0020239566_01 Ultimate 3 Installation and maintenance instructions 3

L Technical data 46

Index 49

1 Safety

4 Installation and maintenance instructions Ultimate 3 0020239566_01

1 Safety

11 Action-related warnings

Classification of action-related warningsThe action-related warnings are classified inaccordance with the severity of the possibledanger using the following warning signs andsignal words

Warning symbols and signal wordsDangerImminent danger to life or risk ofsevere personal injury

DangerRisk of death from electric shock

WarningRisk of minor personal injury

CautionRisk of material or environmentaldamage

12 Risk caused by inadequatequalifications

The following work must only be carried outby competent persons who are sufficientlyqualified to do so

ndash Installationndash Disassemblyndash Installationndash Start-upndash Maintenancendash Repairndash Decommissioning

Observe all instructions that are includedwith the product

Proceed in accordance with the currentstate of technology

Observe all applicable directives stand-ards laws and other regulations

13 Intended use

There is a risk of injury or death to the user orothers or of damage to the product and otherproperty in the event of improper use or usefor which it is not intended

The product is intended as a heat generatorfor closed heating installations and for hotwater generation

Depending on the gas-fired boiler type theproducts referred to in these instructionsmust only be installed and operated in con-junction with the airflue pipe accessories lis-ted in the other applicable documents

Intended use includes the following

ndash observance of accompanying operatinginstallation and servicing instructions forthe product and any other system compon-ents

ndash installing and fitting the product in accord-ance with the product and system approval

ndash compliance with all inspection and main-tenance conditions listed in the instruc-tions

Intended use also covers installation in ac-cordance with the IP class

Any other use that is not specified in theseinstructions or use beyond that specified inthis document shall be considered improperuse Any direct commercial or industrial useis also deemed to be improper

Caution

Improper use of any kind is prohibited

14 General safety information

141 Risk of death from escaping gas

What to do if you smell gas in the building

Avoid rooms that smell of gas If possible open doors and windows fully

and ensure adequate ventilation Do not use naked flames (eg lighters

matches) Do not smoke Do not use any electrical switches mains

plugs doorbells telephones or other com-munication systems in the building

If it is safe to do so close the emergencycontrol valve or the main isolator

Safety 1

0020239566_01 Ultimate 3 Installation and maintenance instructions 5

If possible close the gas isolator cock onthe product

Warn other occupants in the building byyelling or banging on doors or walls

Leave the building immediately and ensurethat others do not enter the building

Notify the gas supply company or the Na-tional Grid +44 (0) 800 111999 by tele-phone once you are outside of the build-ing

142 Risk of death from escaping fluegas

If you operate the product with an empty con-densate siphon flue gas may escape into theroom air

In order to operate the product ensure thatthe condensate siphon is always full

143 Risk of death due to blocked orleaking flue gas routes

Installation errors damage tampering unau-thorised installation sites or similar can causeflue gas to escape and result in a risk of pois-oning

What to do if you smell flue gas in the prop-erty

Open all accessible doors and windowsfully to provide ventilation

Switch off the product Check the flue gas routes in the product

and the flue gas diversions

144 Risk of death due to explosive andflammable materials

Do not use or store explosive or flammablematerials (eg petrol paper paint) in theinstallation room of the product

145 Risk of death from electric shock

There is a risk of death from electric shock ifyou touch live components

Before commencing work on the product

Unplug the mains plug Or disconnect the product from the power

supply by switching off all power supplies(electrical partition with a contact openingof at least 3 mm eg fuse or line protec-tion switch)

Secure against being switched back onagain

Wait for at least 3 minutes until the con-densers have discharged

146 Risk of death due to lack of safetydevices

The schematic drawings included in this doc-ument do not show all safety devices re-quired for correct installation

Install the necessary safety devices in thesystem

Observe the applicable national and inter-national laws standards and guidelines

147 Risk of poisoning and burns causedby escaping hot flue gases

Only operate the product if the airflue pipehas been completely installed

With the exception of short periods fortesting purposes only operate the productwhen the front casing is installed andclosed

148 Risk of being burned or scalded byhot components

Only carry out work on these componentsonce they have cooled down

149 Risk of injury during transport dueto a high product weight

Make sure that the product is transportedby at least two people

1410 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the fluegas guiding

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similar

1 Safety

6 Installation and maintenance instructions Ultimate 3 0020239566_01

locations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the airfluepipe

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1412 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1413 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenscrew connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020239566_01 Ultimate 3 Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Applicability of the instructions

These instructions apply only to

Product article number

Article number Gas Council Num-ber

ULTIMATE 3 30c 0010021404 47-019-55

ULTIMATE 3 35c 0010021405 47-019-57

These products are only designed for natural gas systems

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Serial number

2

3

1

The serial number is located on the identification plate (1)and in the short operating instructions (2) (rarr Page 7)

Stickers showing the serial number are on the back of theelectronics box (3)

33 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

The identification plate keeps record of the country in whichthe product is to be installed

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

For quality control purposes 5th and 6thdigits = week of production

For identification purposes 7th to 16thdigits = product article number

For quality control purposes 17th to 20thdigits = place of manufacture

Ultimate 3 Product designation

XX Gxx ndash xx mbar(x kPa)

Gas group and gas connection pressureas set at the factory

Cat Approved gas category

Condensing techno-logy

Efficiency of the boiler in accordancewith directive 9242EWG

Type Xx3(x) Approved flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

GC no Gas council number

4 Set-up

8 Installation and maintenance instructions Ultimate 3 0020239566_01

34 Functional elements Combination unit

15

131211

9

10

8

6

5

7

4

3

2

1

17

16

19 18

14

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Pressure gauge

5 Condensate siphon

6 Flue gas pipe

7 Pressure sensor

8 Flue gas measuringstub pipe

9 Ignition transformer

10 Gas valve

11 Air intake pipe

12 Ignition electrode

13 Fan

14 Primary heat exchanger

15 Heating expansionvessel

16 Flow rate sensor

17 Heating pump

18 Bypass

19 Diverter valve

35 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend your legs at the knee

Hold the load as close as possible to your body

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete

Quantity Description

1 Heat generator

1

Bag with accessories

ndash Bag with seals

ndash Condensate drain hose

ndash Drain spigot of the expansion relief valve

ndash Hanging bracket

ndash Bag containing the hydraulic connections

1 Enclosed documentation

Set-up 4

0020239566_01 Ultimate 3 Installation and maintenance instructions 9

44 Dimensions

A

C

B

D

Dimensions

A B C D

740 mm 130 mm 300 mm 418 mm

45 Minimum clearances

C C D

AB

Minimum clearances

A B C D

ge 150 mm ge 150 mm ge 0 mm

Note

ge 50 mm (re-quired clear-ance for re-moving theside section)

ge 600 mm

Note

ge 5 mm (forcabinet-typecasing)

46 Clearance from combustible components

It is not necessary to maintain a specified clearance betweenthe product and components made of combustible materials

47 Using the installation template

Use the installation template to ascertain the locations atwhich you need to drill holes and make breakthroughs

48 Wall-mounting the product

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the weight of the product under operatingconditions (operational weight)

2 Wall-mount the product as described using the adaptedfixing material provided on-site

4 Set-up

10 Installation and maintenance instructions Ultimate 3 0020239566_01

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial may be used for the wall

A

B

Wall-mount the product as described

Conditions The load-bearing capacity of the wall is not sufficient

Ensure that wall-mounting apparatus on-site has a suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

49 Removinginstalling the front casing

491 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

492 Fitting the front panel

Refit the components in the reverse order

410 Removinginstalling the side section

4101 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least 50mm) you can remove the side section to facilitatemaintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 3: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Contents

0020239566_01 Ultimate 3 Installation and maintenance instructions 3

L Technical data 46

Index 49

1 Safety

4 Installation and maintenance instructions Ultimate 3 0020239566_01

1 Safety

11 Action-related warnings

Classification of action-related warningsThe action-related warnings are classified inaccordance with the severity of the possibledanger using the following warning signs andsignal words

Warning symbols and signal wordsDangerImminent danger to life or risk ofsevere personal injury

DangerRisk of death from electric shock

WarningRisk of minor personal injury

CautionRisk of material or environmentaldamage

12 Risk caused by inadequatequalifications

The following work must only be carried outby competent persons who are sufficientlyqualified to do so

ndash Installationndash Disassemblyndash Installationndash Start-upndash Maintenancendash Repairndash Decommissioning

Observe all instructions that are includedwith the product

Proceed in accordance with the currentstate of technology

Observe all applicable directives stand-ards laws and other regulations

13 Intended use

There is a risk of injury or death to the user orothers or of damage to the product and otherproperty in the event of improper use or usefor which it is not intended

The product is intended as a heat generatorfor closed heating installations and for hotwater generation

Depending on the gas-fired boiler type theproducts referred to in these instructionsmust only be installed and operated in con-junction with the airflue pipe accessories lis-ted in the other applicable documents

Intended use includes the following

ndash observance of accompanying operatinginstallation and servicing instructions forthe product and any other system compon-ents

ndash installing and fitting the product in accord-ance with the product and system approval

ndash compliance with all inspection and main-tenance conditions listed in the instruc-tions

Intended use also covers installation in ac-cordance with the IP class

Any other use that is not specified in theseinstructions or use beyond that specified inthis document shall be considered improperuse Any direct commercial or industrial useis also deemed to be improper

Caution

Improper use of any kind is prohibited

14 General safety information

141 Risk of death from escaping gas

What to do if you smell gas in the building

Avoid rooms that smell of gas If possible open doors and windows fully

and ensure adequate ventilation Do not use naked flames (eg lighters

matches) Do not smoke Do not use any electrical switches mains

plugs doorbells telephones or other com-munication systems in the building

If it is safe to do so close the emergencycontrol valve or the main isolator

Safety 1

0020239566_01 Ultimate 3 Installation and maintenance instructions 5

If possible close the gas isolator cock onthe product

Warn other occupants in the building byyelling or banging on doors or walls

Leave the building immediately and ensurethat others do not enter the building

Notify the gas supply company or the Na-tional Grid +44 (0) 800 111999 by tele-phone once you are outside of the build-ing

142 Risk of death from escaping fluegas

If you operate the product with an empty con-densate siphon flue gas may escape into theroom air

In order to operate the product ensure thatthe condensate siphon is always full

143 Risk of death due to blocked orleaking flue gas routes

Installation errors damage tampering unau-thorised installation sites or similar can causeflue gas to escape and result in a risk of pois-oning

What to do if you smell flue gas in the prop-erty

Open all accessible doors and windowsfully to provide ventilation

Switch off the product Check the flue gas routes in the product

and the flue gas diversions

144 Risk of death due to explosive andflammable materials

Do not use or store explosive or flammablematerials (eg petrol paper paint) in theinstallation room of the product

145 Risk of death from electric shock

There is a risk of death from electric shock ifyou touch live components

Before commencing work on the product

Unplug the mains plug Or disconnect the product from the power

supply by switching off all power supplies(electrical partition with a contact openingof at least 3 mm eg fuse or line protec-tion switch)

Secure against being switched back onagain

Wait for at least 3 minutes until the con-densers have discharged

146 Risk of death due to lack of safetydevices

The schematic drawings included in this doc-ument do not show all safety devices re-quired for correct installation

Install the necessary safety devices in thesystem

Observe the applicable national and inter-national laws standards and guidelines

147 Risk of poisoning and burns causedby escaping hot flue gases

Only operate the product if the airflue pipehas been completely installed

With the exception of short periods fortesting purposes only operate the productwhen the front casing is installed andclosed

148 Risk of being burned or scalded byhot components

Only carry out work on these componentsonce they have cooled down

149 Risk of injury during transport dueto a high product weight

Make sure that the product is transportedby at least two people

1410 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the fluegas guiding

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similar

1 Safety

6 Installation and maintenance instructions Ultimate 3 0020239566_01

locations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the airfluepipe

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1412 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1413 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenscrew connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020239566_01 Ultimate 3 Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Applicability of the instructions

These instructions apply only to

Product article number

Article number Gas Council Num-ber

ULTIMATE 3 30c 0010021404 47-019-55

ULTIMATE 3 35c 0010021405 47-019-57

These products are only designed for natural gas systems

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Serial number

2

3

1

The serial number is located on the identification plate (1)and in the short operating instructions (2) (rarr Page 7)

Stickers showing the serial number are on the back of theelectronics box (3)

33 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

The identification plate keeps record of the country in whichthe product is to be installed

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

For quality control purposes 5th and 6thdigits = week of production

For identification purposes 7th to 16thdigits = product article number

For quality control purposes 17th to 20thdigits = place of manufacture

Ultimate 3 Product designation

XX Gxx ndash xx mbar(x kPa)

Gas group and gas connection pressureas set at the factory

Cat Approved gas category

Condensing techno-logy

Efficiency of the boiler in accordancewith directive 9242EWG

Type Xx3(x) Approved flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

GC no Gas council number

4 Set-up

8 Installation and maintenance instructions Ultimate 3 0020239566_01

34 Functional elements Combination unit

15

131211

9

10

8

6

5

7

4

3

2

1

17

16

19 18

14

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Pressure gauge

5 Condensate siphon

6 Flue gas pipe

7 Pressure sensor

8 Flue gas measuringstub pipe

9 Ignition transformer

10 Gas valve

11 Air intake pipe

12 Ignition electrode

13 Fan

14 Primary heat exchanger

15 Heating expansionvessel

16 Flow rate sensor

17 Heating pump

18 Bypass

19 Diverter valve

35 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend your legs at the knee

Hold the load as close as possible to your body

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete

Quantity Description

1 Heat generator

1

Bag with accessories

ndash Bag with seals

ndash Condensate drain hose

ndash Drain spigot of the expansion relief valve

ndash Hanging bracket

ndash Bag containing the hydraulic connections

1 Enclosed documentation

Set-up 4

0020239566_01 Ultimate 3 Installation and maintenance instructions 9

44 Dimensions

A

C

B

D

Dimensions

A B C D

740 mm 130 mm 300 mm 418 mm

45 Minimum clearances

C C D

AB

Minimum clearances

A B C D

ge 150 mm ge 150 mm ge 0 mm

Note

ge 50 mm (re-quired clear-ance for re-moving theside section)

ge 600 mm

Note

ge 5 mm (forcabinet-typecasing)

46 Clearance from combustible components

It is not necessary to maintain a specified clearance betweenthe product and components made of combustible materials

47 Using the installation template

Use the installation template to ascertain the locations atwhich you need to drill holes and make breakthroughs

48 Wall-mounting the product

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the weight of the product under operatingconditions (operational weight)

2 Wall-mount the product as described using the adaptedfixing material provided on-site

4 Set-up

10 Installation and maintenance instructions Ultimate 3 0020239566_01

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial may be used for the wall

A

B

Wall-mount the product as described

Conditions The load-bearing capacity of the wall is not sufficient

Ensure that wall-mounting apparatus on-site has a suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

49 Removinginstalling the front casing

491 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

492 Fitting the front panel

Refit the components in the reverse order

410 Removinginstalling the side section

4101 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least 50mm) you can remove the side section to facilitatemaintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 4: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

1 Safety

4 Installation and maintenance instructions Ultimate 3 0020239566_01

1 Safety

11 Action-related warnings

Classification of action-related warningsThe action-related warnings are classified inaccordance with the severity of the possibledanger using the following warning signs andsignal words

Warning symbols and signal wordsDangerImminent danger to life or risk ofsevere personal injury

DangerRisk of death from electric shock

WarningRisk of minor personal injury

CautionRisk of material or environmentaldamage

12 Risk caused by inadequatequalifications

The following work must only be carried outby competent persons who are sufficientlyqualified to do so

ndash Installationndash Disassemblyndash Installationndash Start-upndash Maintenancendash Repairndash Decommissioning

Observe all instructions that are includedwith the product

Proceed in accordance with the currentstate of technology

Observe all applicable directives stand-ards laws and other regulations

13 Intended use

There is a risk of injury or death to the user orothers or of damage to the product and otherproperty in the event of improper use or usefor which it is not intended

The product is intended as a heat generatorfor closed heating installations and for hotwater generation

Depending on the gas-fired boiler type theproducts referred to in these instructionsmust only be installed and operated in con-junction with the airflue pipe accessories lis-ted in the other applicable documents

Intended use includes the following

ndash observance of accompanying operatinginstallation and servicing instructions forthe product and any other system compon-ents

ndash installing and fitting the product in accord-ance with the product and system approval

ndash compliance with all inspection and main-tenance conditions listed in the instruc-tions

Intended use also covers installation in ac-cordance with the IP class

Any other use that is not specified in theseinstructions or use beyond that specified inthis document shall be considered improperuse Any direct commercial or industrial useis also deemed to be improper

Caution

Improper use of any kind is prohibited

14 General safety information

141 Risk of death from escaping gas

What to do if you smell gas in the building

Avoid rooms that smell of gas If possible open doors and windows fully

and ensure adequate ventilation Do not use naked flames (eg lighters

matches) Do not smoke Do not use any electrical switches mains

plugs doorbells telephones or other com-munication systems in the building

If it is safe to do so close the emergencycontrol valve or the main isolator

Safety 1

0020239566_01 Ultimate 3 Installation and maintenance instructions 5

If possible close the gas isolator cock onthe product

Warn other occupants in the building byyelling or banging on doors or walls

Leave the building immediately and ensurethat others do not enter the building

Notify the gas supply company or the Na-tional Grid +44 (0) 800 111999 by tele-phone once you are outside of the build-ing

142 Risk of death from escaping fluegas

If you operate the product with an empty con-densate siphon flue gas may escape into theroom air

In order to operate the product ensure thatthe condensate siphon is always full

143 Risk of death due to blocked orleaking flue gas routes

Installation errors damage tampering unau-thorised installation sites or similar can causeflue gas to escape and result in a risk of pois-oning

What to do if you smell flue gas in the prop-erty

Open all accessible doors and windowsfully to provide ventilation

Switch off the product Check the flue gas routes in the product

and the flue gas diversions

144 Risk of death due to explosive andflammable materials

Do not use or store explosive or flammablematerials (eg petrol paper paint) in theinstallation room of the product

145 Risk of death from electric shock

There is a risk of death from electric shock ifyou touch live components

Before commencing work on the product

Unplug the mains plug Or disconnect the product from the power

supply by switching off all power supplies(electrical partition with a contact openingof at least 3 mm eg fuse or line protec-tion switch)

Secure against being switched back onagain

Wait for at least 3 minutes until the con-densers have discharged

146 Risk of death due to lack of safetydevices

The schematic drawings included in this doc-ument do not show all safety devices re-quired for correct installation

Install the necessary safety devices in thesystem

Observe the applicable national and inter-national laws standards and guidelines

147 Risk of poisoning and burns causedby escaping hot flue gases

Only operate the product if the airflue pipehas been completely installed

With the exception of short periods fortesting purposes only operate the productwhen the front casing is installed andclosed

148 Risk of being burned or scalded byhot components

Only carry out work on these componentsonce they have cooled down

149 Risk of injury during transport dueto a high product weight

Make sure that the product is transportedby at least two people

1410 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the fluegas guiding

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similar

1 Safety

6 Installation and maintenance instructions Ultimate 3 0020239566_01

locations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the airfluepipe

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1412 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1413 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenscrew connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020239566_01 Ultimate 3 Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Applicability of the instructions

These instructions apply only to

Product article number

Article number Gas Council Num-ber

ULTIMATE 3 30c 0010021404 47-019-55

ULTIMATE 3 35c 0010021405 47-019-57

These products are only designed for natural gas systems

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Serial number

2

3

1

The serial number is located on the identification plate (1)and in the short operating instructions (2) (rarr Page 7)

Stickers showing the serial number are on the back of theelectronics box (3)

33 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

The identification plate keeps record of the country in whichthe product is to be installed

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

For quality control purposes 5th and 6thdigits = week of production

For identification purposes 7th to 16thdigits = product article number

For quality control purposes 17th to 20thdigits = place of manufacture

Ultimate 3 Product designation

XX Gxx ndash xx mbar(x kPa)

Gas group and gas connection pressureas set at the factory

Cat Approved gas category

Condensing techno-logy

Efficiency of the boiler in accordancewith directive 9242EWG

Type Xx3(x) Approved flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

GC no Gas council number

4 Set-up

8 Installation and maintenance instructions Ultimate 3 0020239566_01

34 Functional elements Combination unit

15

131211

9

10

8

6

5

7

4

3

2

1

17

16

19 18

14

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Pressure gauge

5 Condensate siphon

6 Flue gas pipe

7 Pressure sensor

8 Flue gas measuringstub pipe

9 Ignition transformer

10 Gas valve

11 Air intake pipe

12 Ignition electrode

13 Fan

14 Primary heat exchanger

15 Heating expansionvessel

16 Flow rate sensor

17 Heating pump

18 Bypass

19 Diverter valve

35 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend your legs at the knee

Hold the load as close as possible to your body

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete

Quantity Description

1 Heat generator

1

Bag with accessories

ndash Bag with seals

ndash Condensate drain hose

ndash Drain spigot of the expansion relief valve

ndash Hanging bracket

ndash Bag containing the hydraulic connections

1 Enclosed documentation

Set-up 4

0020239566_01 Ultimate 3 Installation and maintenance instructions 9

44 Dimensions

A

C

B

D

Dimensions

A B C D

740 mm 130 mm 300 mm 418 mm

45 Minimum clearances

C C D

AB

Minimum clearances

A B C D

ge 150 mm ge 150 mm ge 0 mm

Note

ge 50 mm (re-quired clear-ance for re-moving theside section)

ge 600 mm

Note

ge 5 mm (forcabinet-typecasing)

46 Clearance from combustible components

It is not necessary to maintain a specified clearance betweenthe product and components made of combustible materials

47 Using the installation template

Use the installation template to ascertain the locations atwhich you need to drill holes and make breakthroughs

48 Wall-mounting the product

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the weight of the product under operatingconditions (operational weight)

2 Wall-mount the product as described using the adaptedfixing material provided on-site

4 Set-up

10 Installation and maintenance instructions Ultimate 3 0020239566_01

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial may be used for the wall

A

B

Wall-mount the product as described

Conditions The load-bearing capacity of the wall is not sufficient

Ensure that wall-mounting apparatus on-site has a suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

49 Removinginstalling the front casing

491 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

492 Fitting the front panel

Refit the components in the reverse order

410 Removinginstalling the side section

4101 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least 50mm) you can remove the side section to facilitatemaintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 5: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Safety 1

0020239566_01 Ultimate 3 Installation and maintenance instructions 5

If possible close the gas isolator cock onthe product

Warn other occupants in the building byyelling or banging on doors or walls

Leave the building immediately and ensurethat others do not enter the building

Notify the gas supply company or the Na-tional Grid +44 (0) 800 111999 by tele-phone once you are outside of the build-ing

142 Risk of death from escaping fluegas

If you operate the product with an empty con-densate siphon flue gas may escape into theroom air

In order to operate the product ensure thatthe condensate siphon is always full

143 Risk of death due to blocked orleaking flue gas routes

Installation errors damage tampering unau-thorised installation sites or similar can causeflue gas to escape and result in a risk of pois-oning

What to do if you smell flue gas in the prop-erty

Open all accessible doors and windowsfully to provide ventilation

Switch off the product Check the flue gas routes in the product

and the flue gas diversions

144 Risk of death due to explosive andflammable materials

Do not use or store explosive or flammablematerials (eg petrol paper paint) in theinstallation room of the product

145 Risk of death from electric shock

There is a risk of death from electric shock ifyou touch live components

Before commencing work on the product

Unplug the mains plug Or disconnect the product from the power

supply by switching off all power supplies(electrical partition with a contact openingof at least 3 mm eg fuse or line protec-tion switch)

Secure against being switched back onagain

Wait for at least 3 minutes until the con-densers have discharged

146 Risk of death due to lack of safetydevices

The schematic drawings included in this doc-ument do not show all safety devices re-quired for correct installation

Install the necessary safety devices in thesystem

Observe the applicable national and inter-national laws standards and guidelines

147 Risk of poisoning and burns causedby escaping hot flue gases

Only operate the product if the airflue pipehas been completely installed

With the exception of short periods fortesting purposes only operate the productwhen the front casing is installed andclosed

148 Risk of being burned or scalded byhot components

Only carry out work on these componentsonce they have cooled down

149 Risk of injury during transport dueto a high product weight

Make sure that the product is transportedby at least two people

1410 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the fluegas guiding

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similar

1 Safety

6 Installation and maintenance instructions Ultimate 3 0020239566_01

locations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the airfluepipe

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1412 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1413 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenscrew connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020239566_01 Ultimate 3 Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Applicability of the instructions

These instructions apply only to

Product article number

Article number Gas Council Num-ber

ULTIMATE 3 30c 0010021404 47-019-55

ULTIMATE 3 35c 0010021405 47-019-57

These products are only designed for natural gas systems

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Serial number

2

3

1

The serial number is located on the identification plate (1)and in the short operating instructions (2) (rarr Page 7)

Stickers showing the serial number are on the back of theelectronics box (3)

33 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

The identification plate keeps record of the country in whichthe product is to be installed

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

For quality control purposes 5th and 6thdigits = week of production

For identification purposes 7th to 16thdigits = product article number

For quality control purposes 17th to 20thdigits = place of manufacture

Ultimate 3 Product designation

XX Gxx ndash xx mbar(x kPa)

Gas group and gas connection pressureas set at the factory

Cat Approved gas category

Condensing techno-logy

Efficiency of the boiler in accordancewith directive 9242EWG

Type Xx3(x) Approved flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

GC no Gas council number

4 Set-up

8 Installation and maintenance instructions Ultimate 3 0020239566_01

34 Functional elements Combination unit

15

131211

9

10

8

6

5

7

4

3

2

1

17

16

19 18

14

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Pressure gauge

5 Condensate siphon

6 Flue gas pipe

7 Pressure sensor

8 Flue gas measuringstub pipe

9 Ignition transformer

10 Gas valve

11 Air intake pipe

12 Ignition electrode

13 Fan

14 Primary heat exchanger

15 Heating expansionvessel

16 Flow rate sensor

17 Heating pump

18 Bypass

19 Diverter valve

35 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend your legs at the knee

Hold the load as close as possible to your body

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete

Quantity Description

1 Heat generator

1

Bag with accessories

ndash Bag with seals

ndash Condensate drain hose

ndash Drain spigot of the expansion relief valve

ndash Hanging bracket

ndash Bag containing the hydraulic connections

1 Enclosed documentation

Set-up 4

0020239566_01 Ultimate 3 Installation and maintenance instructions 9

44 Dimensions

A

C

B

D

Dimensions

A B C D

740 mm 130 mm 300 mm 418 mm

45 Minimum clearances

C C D

AB

Minimum clearances

A B C D

ge 150 mm ge 150 mm ge 0 mm

Note

ge 50 mm (re-quired clear-ance for re-moving theside section)

ge 600 mm

Note

ge 5 mm (forcabinet-typecasing)

46 Clearance from combustible components

It is not necessary to maintain a specified clearance betweenthe product and components made of combustible materials

47 Using the installation template

Use the installation template to ascertain the locations atwhich you need to drill holes and make breakthroughs

48 Wall-mounting the product

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the weight of the product under operatingconditions (operational weight)

2 Wall-mount the product as described using the adaptedfixing material provided on-site

4 Set-up

10 Installation and maintenance instructions Ultimate 3 0020239566_01

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial may be used for the wall

A

B

Wall-mount the product as described

Conditions The load-bearing capacity of the wall is not sufficient

Ensure that wall-mounting apparatus on-site has a suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

49 Removinginstalling the front casing

491 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

492 Fitting the front panel

Refit the components in the reverse order

410 Removinginstalling the side section

4101 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least 50mm) you can remove the side section to facilitatemaintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 6: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

1 Safety

6 Installation and maintenance instructions Ultimate 3 0020239566_01

locations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the airfluepipe

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1412 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1413 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenscrew connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020239566_01 Ultimate 3 Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Applicability of the instructions

These instructions apply only to

Product article number

Article number Gas Council Num-ber

ULTIMATE 3 30c 0010021404 47-019-55

ULTIMATE 3 35c 0010021405 47-019-57

These products are only designed for natural gas systems

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Serial number

2

3

1

The serial number is located on the identification plate (1)and in the short operating instructions (2) (rarr Page 7)

Stickers showing the serial number are on the back of theelectronics box (3)

33 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

The identification plate keeps record of the country in whichthe product is to be installed

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

For quality control purposes 5th and 6thdigits = week of production

For identification purposes 7th to 16thdigits = product article number

For quality control purposes 17th to 20thdigits = place of manufacture

Ultimate 3 Product designation

XX Gxx ndash xx mbar(x kPa)

Gas group and gas connection pressureas set at the factory

Cat Approved gas category

Condensing techno-logy

Efficiency of the boiler in accordancewith directive 9242EWG

Type Xx3(x) Approved flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

GC no Gas council number

4 Set-up

8 Installation and maintenance instructions Ultimate 3 0020239566_01

34 Functional elements Combination unit

15

131211

9

10

8

6

5

7

4

3

2

1

17

16

19 18

14

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Pressure gauge

5 Condensate siphon

6 Flue gas pipe

7 Pressure sensor

8 Flue gas measuringstub pipe

9 Ignition transformer

10 Gas valve

11 Air intake pipe

12 Ignition electrode

13 Fan

14 Primary heat exchanger

15 Heating expansionvessel

16 Flow rate sensor

17 Heating pump

18 Bypass

19 Diverter valve

35 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend your legs at the knee

Hold the load as close as possible to your body

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete

Quantity Description

1 Heat generator

1

Bag with accessories

ndash Bag with seals

ndash Condensate drain hose

ndash Drain spigot of the expansion relief valve

ndash Hanging bracket

ndash Bag containing the hydraulic connections

1 Enclosed documentation

Set-up 4

0020239566_01 Ultimate 3 Installation and maintenance instructions 9

44 Dimensions

A

C

B

D

Dimensions

A B C D

740 mm 130 mm 300 mm 418 mm

45 Minimum clearances

C C D

AB

Minimum clearances

A B C D

ge 150 mm ge 150 mm ge 0 mm

Note

ge 50 mm (re-quired clear-ance for re-moving theside section)

ge 600 mm

Note

ge 5 mm (forcabinet-typecasing)

46 Clearance from combustible components

It is not necessary to maintain a specified clearance betweenthe product and components made of combustible materials

47 Using the installation template

Use the installation template to ascertain the locations atwhich you need to drill holes and make breakthroughs

48 Wall-mounting the product

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the weight of the product under operatingconditions (operational weight)

2 Wall-mount the product as described using the adaptedfixing material provided on-site

4 Set-up

10 Installation and maintenance instructions Ultimate 3 0020239566_01

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial may be used for the wall

A

B

Wall-mount the product as described

Conditions The load-bearing capacity of the wall is not sufficient

Ensure that wall-mounting apparatus on-site has a suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

49 Removinginstalling the front casing

491 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

492 Fitting the front panel

Refit the components in the reverse order

410 Removinginstalling the side section

4101 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least 50mm) you can remove the side section to facilitatemaintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 7: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Notes on the documentation 2

0020239566_01 Ultimate 3 Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Applicability of the instructions

These instructions apply only to

Product article number

Article number Gas Council Num-ber

ULTIMATE 3 30c 0010021404 47-019-55

ULTIMATE 3 35c 0010021405 47-019-57

These products are only designed for natural gas systems

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Serial number

2

3

1

The serial number is located on the identification plate (1)and in the short operating instructions (2) (rarr Page 7)

Stickers showing the serial number are on the back of theelectronics box (3)

33 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

The identification plate keeps record of the country in whichthe product is to be installed

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

For quality control purposes 5th and 6thdigits = week of production

For identification purposes 7th to 16thdigits = product article number

For quality control purposes 17th to 20thdigits = place of manufacture

Ultimate 3 Product designation

XX Gxx ndash xx mbar(x kPa)

Gas group and gas connection pressureas set at the factory

Cat Approved gas category

Condensing techno-logy

Efficiency of the boiler in accordancewith directive 9242EWG

Type Xx3(x) Approved flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

GC no Gas council number

4 Set-up

8 Installation and maintenance instructions Ultimate 3 0020239566_01

34 Functional elements Combination unit

15

131211

9

10

8

6

5

7

4

3

2

1

17

16

19 18

14

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Pressure gauge

5 Condensate siphon

6 Flue gas pipe

7 Pressure sensor

8 Flue gas measuringstub pipe

9 Ignition transformer

10 Gas valve

11 Air intake pipe

12 Ignition electrode

13 Fan

14 Primary heat exchanger

15 Heating expansionvessel

16 Flow rate sensor

17 Heating pump

18 Bypass

19 Diverter valve

35 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend your legs at the knee

Hold the load as close as possible to your body

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete

Quantity Description

1 Heat generator

1

Bag with accessories

ndash Bag with seals

ndash Condensate drain hose

ndash Drain spigot of the expansion relief valve

ndash Hanging bracket

ndash Bag containing the hydraulic connections

1 Enclosed documentation

Set-up 4

0020239566_01 Ultimate 3 Installation and maintenance instructions 9

44 Dimensions

A

C

B

D

Dimensions

A B C D

740 mm 130 mm 300 mm 418 mm

45 Minimum clearances

C C D

AB

Minimum clearances

A B C D

ge 150 mm ge 150 mm ge 0 mm

Note

ge 50 mm (re-quired clear-ance for re-moving theside section)

ge 600 mm

Note

ge 5 mm (forcabinet-typecasing)

46 Clearance from combustible components

It is not necessary to maintain a specified clearance betweenthe product and components made of combustible materials

47 Using the installation template

Use the installation template to ascertain the locations atwhich you need to drill holes and make breakthroughs

48 Wall-mounting the product

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the weight of the product under operatingconditions (operational weight)

2 Wall-mount the product as described using the adaptedfixing material provided on-site

4 Set-up

10 Installation and maintenance instructions Ultimate 3 0020239566_01

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial may be used for the wall

A

B

Wall-mount the product as described

Conditions The load-bearing capacity of the wall is not sufficient

Ensure that wall-mounting apparatus on-site has a suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

49 Removinginstalling the front casing

491 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

492 Fitting the front panel

Refit the components in the reverse order

410 Removinginstalling the side section

4101 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least 50mm) you can remove the side section to facilitatemaintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 8: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

4 Set-up

8 Installation and maintenance instructions Ultimate 3 0020239566_01

34 Functional elements Combination unit

15

131211

9

10

8

6

5

7

4

3

2

1

17

16

19 18

14

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Pressure gauge

5 Condensate siphon

6 Flue gas pipe

7 Pressure sensor

8 Flue gas measuringstub pipe

9 Ignition transformer

10 Gas valve

11 Air intake pipe

12 Ignition electrode

13 Fan

14 Primary heat exchanger

15 Heating expansionvessel

16 Flow rate sensor

17 Heating pump

18 Bypass

19 Diverter valve

35 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend your legs at the knee

Hold the load as close as possible to your body

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete

Quantity Description

1 Heat generator

1

Bag with accessories

ndash Bag with seals

ndash Condensate drain hose

ndash Drain spigot of the expansion relief valve

ndash Hanging bracket

ndash Bag containing the hydraulic connections

1 Enclosed documentation

Set-up 4

0020239566_01 Ultimate 3 Installation and maintenance instructions 9

44 Dimensions

A

C

B

D

Dimensions

A B C D

740 mm 130 mm 300 mm 418 mm

45 Minimum clearances

C C D

AB

Minimum clearances

A B C D

ge 150 mm ge 150 mm ge 0 mm

Note

ge 50 mm (re-quired clear-ance for re-moving theside section)

ge 600 mm

Note

ge 5 mm (forcabinet-typecasing)

46 Clearance from combustible components

It is not necessary to maintain a specified clearance betweenthe product and components made of combustible materials

47 Using the installation template

Use the installation template to ascertain the locations atwhich you need to drill holes and make breakthroughs

48 Wall-mounting the product

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the weight of the product under operatingconditions (operational weight)

2 Wall-mount the product as described using the adaptedfixing material provided on-site

4 Set-up

10 Installation and maintenance instructions Ultimate 3 0020239566_01

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial may be used for the wall

A

B

Wall-mount the product as described

Conditions The load-bearing capacity of the wall is not sufficient

Ensure that wall-mounting apparatus on-site has a suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

49 Removinginstalling the front casing

491 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

492 Fitting the front panel

Refit the components in the reverse order

410 Removinginstalling the side section

4101 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least 50mm) you can remove the side section to facilitatemaintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 9: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Set-up 4

0020239566_01 Ultimate 3 Installation and maintenance instructions 9

44 Dimensions

A

C

B

D

Dimensions

A B C D

740 mm 130 mm 300 mm 418 mm

45 Minimum clearances

C C D

AB

Minimum clearances

A B C D

ge 150 mm ge 150 mm ge 0 mm

Note

ge 50 mm (re-quired clear-ance for re-moving theside section)

ge 600 mm

Note

ge 5 mm (forcabinet-typecasing)

46 Clearance from combustible components

It is not necessary to maintain a specified clearance betweenthe product and components made of combustible materials

47 Using the installation template

Use the installation template to ascertain the locations atwhich you need to drill holes and make breakthroughs

48 Wall-mounting the product

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the weight of the product under operatingconditions (operational weight)

2 Wall-mount the product as described using the adaptedfixing material provided on-site

4 Set-up

10 Installation and maintenance instructions Ultimate 3 0020239566_01

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial may be used for the wall

A

B

Wall-mount the product as described

Conditions The load-bearing capacity of the wall is not sufficient

Ensure that wall-mounting apparatus on-site has a suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

49 Removinginstalling the front casing

491 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

492 Fitting the front panel

Refit the components in the reverse order

410 Removinginstalling the side section

4101 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least 50mm) you can remove the side section to facilitatemaintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 10: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

4 Set-up

10 Installation and maintenance instructions Ultimate 3 0020239566_01

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial may be used for the wall

A

B

Wall-mount the product as described

Conditions The load-bearing capacity of the wall is not sufficient

Ensure that wall-mounting apparatus on-site has a suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

49 Removinginstalling the front casing

491 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

492 Fitting the front panel

Refit the components in the reverse order

410 Removinginstalling the side section

4101 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least 50mm) you can remove the side section to facilitatemaintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 11: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 11

4102 Installing the side section

Refit the components in the reverse order

5 Installation

DangerRisk of explosion or scalding caused byincorrect installation

Stresses in the supply line can cause leaks

Make sure there is no stress in the supplylines when they are installed

CautionRisk of damage caused by contaminatedlines

Foreign bodies such as welding remnantssealing residue or dirt in the water pipes maycause damage to the boiler

Flush the heating installation thoroughlyprior to installation

51 Checking the gas meter

Make sure that the existing gas meter is capable ofpassing the rate of gas supply required

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of damage caused by corrosion

If non-diffusion-tight plastic pipes are used inthe heating installation this may cause air toenter the heating water and corrosion of theheat generation circuit and the boiler

If using non-diffusion-tight plastic pipesin the heating installation separate thesystem by installing an external heat ex-changer between the boiler and the heat-ing installation

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connection pieces if the con-nection pieces are not yet screwed to theservice valves

Note

Apply thermal insulation to the water pipes to theboiler outlet and to the system

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the system

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return flap at the products outlet(heating flow)

2 Ensure that the system has the following components

ndash A cold water stop cock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas line before start-up

3 Check whether the connections (rarr Page 19) are leak-tight

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 12: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

5 Installation

12 Installation and maintenance instructions Ultimate 3 0020239566_01

53 Connecting the drain line for the expansionrelief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The components must be set up in such a way thatyou can see the water flowing out

54 Connecting the condensate drain pipework

1

2

Follow the instructions listed here and observe directivesand local regulations on condensed water discharge

Use PVC or another material that is suitable for drainingthe non-neutralised condensed water

If you cannot guarantee that the materials from whichthe drain lines are made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate siphon (1) Use the supplieddrain hose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat loading under 70 kW

55 Connecting the drain cock

1

Connect a hose to the drain cock (1) and guide the freeend of the hose to a suitable outflow location

56 Electrical installation

DangerRisk of death from electric shock

The mains connection terminals L and N re-main live even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

561 Opening and closing the electronics box

B

B

A

1 To open the electronics box follow the instructions inthe specified sequence

2 To close the electronics box follow the instructions inreverse order

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 13: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Installation 5

0020239566_01 Ultimate 3 Installation and maintenance instructions 13

562 Cable route

230V

24V eBus

1 24-V eBUS cable route

2 230-V eBUS cable route

563 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

564 Establishing the power supply

1

1 Observe all valid regulations

ndash The applicable regulations state that the connectionmust be made via an electrical partition with a con-tact opening of at least 3 mm at each pole

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Cover plate le 3 A

4 Open the electronics box

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 13)

7 Screw the supplied plug to a three-core mains connec-tion cable that complies with the relevant standards

8 Connect the plug for the mains connection cable

9 Make sure that access to the mains connection is al-ways available and is not covered or blocked

10 Close the electronics box

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 14: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

6 Operation

14 Installation and maintenance instructions Ultimate 3 0020239566_01

565 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box

2 Carry out the wiring (rarr Page 13)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 15: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 15

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled in and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the factory setting

CautionRisk of material damage caused by mak-ing unauthorised settings

Never modify the factory setting of the gaspressure regulator of the gas valve

The product combustion is checked on-site and pre-set tothe type of gas specified on the identification plate

Check the information about the type of gas indicated onthe identification plate and compare this with the type ofgas available at the installation location

Conditions The product model is not compatible with the local gas type

Do not start up the product

Conditions The product model is compatible with the local gas type

Proceed as described below

73 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the system check the qualityof the heating water

Checking the quality of the heating water Remove a little water from the heating circuit

Check the appearance of the heating water

If you ascertain that it contains sedimentary materialsyou must desludge the system

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the sys-tem and apply suitable corrosion-protection measures orfit a magnet filter

Check the pH value of the removed water at 25 degC

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 16: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

7 Start-up

16 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the filling and supplementary water Before filling the system measure the hardness of the

filling and supplementary water

Treating the filling and supplementary water Observe all applicable national regulations and technical

standards when treating the filling and supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in thesystemndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the systemndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe operator about the measures that are required

Inform the operator about the measures required for frostprotection

74 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 17: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 17

75 Switching on the product

Switch on the product via the main switch installed on-site

76 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

77 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

78 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

79 Checking and adjusting the gas ratiosetting

Only a qualified competent person is authorised to imple-ment the settings on the gas valve

Each destroyed seal must be restored

The CO2 adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve

791 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 18: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

7 Start-up

18 Installation and maintenance instructions Ultimate 3 0020239566_01

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

792 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas isolator cock (1)

3 Undo the sealing screw on the measuring nipple (2)

4 Connect a pressure gauge to the measuring nipple (2)

5 Open the gas isolator cock (1)

6 Start up the product with check programme P01(system with eBUS controller) or P03 (system withouteBUS controller)

7 In addition ensure that maximum heat can be dissip-ated into the heating system by turning up the roomthermostat

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Natural gas G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas isolator cock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Close the gas isolator cock (1)

Fit the front panel (rarr Page 10)

Disconnect the product from the power mains

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas isolator cock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas isolator cock (1)

Check the measuring nipple for gas tightness

Fit the front panel (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 19: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Start-up 7

0020239566_01 Ultimate 3 Installation and maintenance instructions 19

793 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

794 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 17)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Fit the front panel (rarr Page 10)

795 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

710 Checking leak-tightness

Check the gas line the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been sealed sothat it is leak-tight

7101 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Purge the heating installation

5 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 20: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

8 Adapting the unit to the heating installation

20 Installation and maintenance instructions Ultimate 3 0020239566_01

7102 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 14)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

To prevent frequent switching on and off of the burner andthus prevent energy losses an electronic restart lockoutis activated for a specific period each time the burner isswitched off The burner anti-cycling time is only active forthe heating mode Hot water handling mode during a burneranti-cycling time does not affect the time function element

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

Conditions Two-stage pump

If required use diagnostics code d19 to adjust the set-ting for the operating-mode-dependent pump speed

Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

21

3

4

6070

50

3020

40

10

0 500 1000 1500 A

B

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass

Conditions Two-stage pump

1

Remove the front casing (rarr Page 10)

Regulate the pressure using the adjusting screw (1)

Fit the front panel (rarr Page 10)

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 21: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Adjusting the hot water temperature 9

0020239566_01 Ultimate 3 Installation and maintenance instructions 21

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

9 Adjusting the hot water temperature

You can resetchange the system parameters (rarr sectionUsing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

91 Setting the hot water temperature

DangerRisk of death from Legionella

Legionella multiply at temperatures below60 degC

Ensure that the operator is familiar with allof the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

10 Handing the product over to theoperator

When you have finished the installation attach the stickersupplied (in the operators language) to the productcover

Explain to the operator how the safety devices work andwhere they are located

Inform the operator how to handle the product

In particular draw attention to the safety informationwhich the operator must follow

Inform the operator of the necessity to have the productmaintained on a regular basis

Instruct the operator about measures taken to ensure thesupply of combustion air and flue gas pipe

11 Inspection and maintenance

111 Observing inspection and maintenanceintervals

Note

Use only new seals and oring Do not use addi-tional compounds

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

112 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

113 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 22: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

11 Inspection and maintenance

22 Installation and maintenance instructions Ultimate 3 0020239566_01

Checking the CO₂ content

Great Bri-tain

Removedfront cas-inginstalledfront casing

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 22)

114 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO₂ at fullload

92 plusmn02

Set forWobbeindex W₀

1409 kWsdothmsup3

O₂ at fullload

45 plusmn18 vol

Great Britain

Removed front cas-inginstalled frontcasing

Natural gas

G20

CO at fullload

le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

115 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 23: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Inspection and maintenance 11

0020239566_01 Ultimate 3 Installation and maintenance instructions 23

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

116 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

2 Clean the ribs of the heat exchanger (1) with water

◁ The water runs out into the condensate tray

117 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

118 Checking the ignition electrode

1

2

3 4 5

1 Disconnect the connection (2) and the earthing cable(1)

2 Remove the fixing screws (3)

3 Carefully remove the electrode from the combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

6 Make sure that the seal (5) is free from damage

If necessary replace the seal

119 Cleaning the condensate tray

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 24: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

11 Inspection and maintenance

24 Installation and maintenance instructions Ultimate 3 0020239566_01

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

1

7 Using water to clean the condensate tray (1)

◁ The water runs out into the condensate siphon

1110 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1111 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 25: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 25

1112 Cleaning the heating filter

2

1

1 Drain the product (rarr Page 25)

2 Remove the temperature sensor (1)

3 Remove the upper clip (2)

4

35

4 Remove the lower clip (3)

5 Remove the flow pipe (4)

6 Remove the heating filter (5) and clean it

7 Refit the components in the reverse order

1113 Installing the gas-air mixture unit

1 Install the burner

2 Install the gas-air mixture unit

3 Install the air intake pipe

4 Install the flue gas pipe

1114 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 15)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1115 Checking the pre-charge pressure of theexpansion vessel

1 Drain the product (rarr Page 25)

2 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Check that the drain valve isopen when topping up

3 If water escapes from the valve of the expansionvessel you must replace the expansion vessel(rarr Page 27)

4 Fill and purge the heating installation (rarr Page 17)

1116 Completing inspection and maintenancework

1 Fill and purge the heating installation (rarr Page 17)

2 Check the gas connection pressure (gas flow pressure)(rarr Page 18)

3 Check the CO₂ content (rarr Page 21)

12 Troubleshooting

121 Rectifying faults

If fault codes (FXX) are present refer to the table in theappendix for advice or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several faults occur at the same time the fault codes areshown alternately on the display

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

122 Calling up the fault memory

The last ten fault codes are stored in the fault memory

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

123 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 26: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

12 Troubleshooting

26 Installation and maintenance instructions Ultimate 3 0020239566_01

124 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 14)

Overview of diagnostics codes (rarr Page 30)

125 Preparing the repair work

1 Decommission the product

2 Disconnect the product from the power mains

3 Remove the front casing

4 Close the gas isolator cock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals

126 Replacing defective components

1261 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 22)

2 Remove the burner seal

3 Remove the burner

4 Install the new burner complete with new seal on theheat exchanger

5 Install the gas-air mixture unit (rarr Page 25)

1262 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 22)

2 Install the new gas-air mixture unit (rarr Page 25)

1263 Replacing the gas valve

1 Disconnect the product from the power mains

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

B

D

E

A

C

5

6

7

3

21

4

4 Remove the air intake pipe (2)

5 Remove the plug from the gas valve (3) and from thefan (4)

6 Unscrew the gas connection pipes connection (1) fromthe gas valve

7 Undo the two screws (5)

8 Remove the gas valve (3)

9 Remove the seal (6) if it is still in place on the fan (7)

10 Install the new gas valve in reverse order

11 Check the CO₂ content (rarr Page 21)

12 Set the CO₂ content (rarr Page 22)

1264 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 22)

1 A

B

3 Remove the gas pipe (1)

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 27: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Troubleshooting 12

0020239566_01 Ultimate 3 Installation and maintenance instructions 27

1

2

3

5 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (5)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

3

4

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

1

2

B

C

A

13 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

14 Remove the ignition transformer (1)

15 Remove the ignition electrode (2)

16 Use the screws to secure the ignition transformer andthe ignition electrode to the new heat exchanger

17 Install the new heat exchanger in reverse order

1265 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

1266 Replacing the expansion vessel

1 Drain the product (rarr Page 25)

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 28: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

12 Troubleshooting

28 Installation and maintenance instructions Ultimate 3 0020239566_01

B

C

1

2

3A

D

2 Undo the nut (3)

3 Remove both screws on the support plate (1)

4 Remove the support plate

5 Pull out the expansion vessel (2) towards the front

6 Insert a new expansion vessel into the product

7 Screw the new expansion vessel onto the water con-nection To do this use a new seal

8 Attach the support plate using both screws

9 Fill and purge the product and if necessary the heatinginstallation

1267 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

2 Pull all of the plugs out from the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1268 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

2 Pull the plug out of the PCB

3 Undo the clips on the PCB

4 Remove the PCB

5 Install the new PCB in such a way that it clicks into thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1269 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 29: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Decommissioning the product 13

0020239566_01 Ultimate 3 Installation and maintenance instructions 29

12610 Replacing the flow sensor

1B

A

1 Push the volume flow sensors handle towards the rearof the boiler

2 Pull the volume flow sensor (1) out of its holder

3 Remove the plug from the volume flow sensor

4 Connect the plug to the new volume flow sensor

5 Insert the volume flow sensor into its holder and ensurethat the plug cable is not damaged

6 Lock the volume flow sensor into its position as soon asit is positioned correctly

12611 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

127 Completing repair work

Check that the product is running correctly and that it iscompletely leak-tight

13 Decommissioning the product

Decommission the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

Drain the product (rarr Page 25)

14 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 30: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

30 Installation and maintenance instructions Ultimate 3 0020239566_01

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 Purging the heating circuit

The diverter valve is moved to the heating position

The function is activated in the heating circuit for 15 minutes

The pump runs and stops at regular intervals

If required this function can be manually switched off

P07 Purging the hot water circuit

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

The pump runs and stops at regular intervals

If required this function can be manually switched off

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute

This function cannot be manually switched off

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 31: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 32: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

32 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 33: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 34: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

34 Installation and maintenance instructions Ultimate 3 0020239566_01

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 35: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Protection mode Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating and hot water request blocked

S97 Automatic test programme Water pressure sensor heating and hot water request blocked

S98 Automatic test programme Return temperature sensor heating and hot water request blocked

S99 Automatic filling active

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) black discharge via ignition cable ignitionplug or ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

Pump blocked insufficient pump output air in product flow and return NTCsensors connected the wrong way round

F24 Safety switch-off Temperature rise toofast

Pump blocked reduced pump output air in product system pressure toolow return flow prevention blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety temperature limiter(STB) break in cable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 36: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

36 Installation and maintenance instructions Ultimate 3 0020239566_01

Fault code Meaning Possible cause

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Replace the screen and PCB at the same time without reconfiguring theproducts Device Specific Number

F71 Fault Flowreturn temperature sensor Flow temperature sensor specifies a constant value Flow temperaturesensor incorrectly attached to the flow pipe flow temperature sensor de-fective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort to earthin supply line to water pressure sensor or water pressure sensor defective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure sensor or pump defective or low water pressure

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

Link box connected but hot water NTC not bridged

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F83 Fault Dry fire When the burner starts the temperature change recorded by the flow orreturn temperature sensor is non-existent or too small Insufficient water inthe product flow or return temperature sensor incorrectly attached to thepipe

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Ignition electrode Ignition electrode not connected properly short circuit in the cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 37: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 37

E Connection diagram Combination unit

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 38: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

38 Installation and maintenance instructions Ultimate 3 0020239566_01

F Connection diagram Combination unit (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor in the heating flow

5 Temperature sensor in the heating return

6 Fan

7 Gas valve

8 3-way valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition device

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 39: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Maintenance(must be

carried out atregular

intervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant In-stallation Manual

X X

2Check the general condition of the product Remove any dirt from the product and the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular atten-tion to signs of corrosion rust and other defects If you notice any damage carry out mainten-ance work

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure isnot within the specified range carry out maintenance work

X X

5 Check the CO₂ content (air ratio) of the product and if necessary adjust it X X

6Disconnect the product from the power mains Check that the plug connections and electricalconnections are correct and make any necessary adjustments

X X

7 Close the gas isolator cock and the service valves X

8Drain the product on the water side Check the pre-charge pressure of the expansion vesseland top up the vessel if necessary (approx 003 MPa03 bar under the system filling pres-sure)

X

9 Check the ignition electrode X X

10 Remove the gas-air mixture unit X

11Replace both burner seals each time it is opened and accordingly each time maintenancework is carried out

X

12Clean the heat exchanger

rarr Section Cleaning the heat exchangerX

13 Check the burner for damage and replace it if necessary X

14Check the condensate siphon in the product clean it and if required replace it

rarr Section Cleaning the condensate siphonX X

15 Install the gas-air mixture unit Caution Replace the seals X

16If necessary if the hot water output is insufficient or the outlet temperature is not reachedreplace the plate heat exchanger

X

17Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged If this is the case also check that the impeller sensor is not dirty ordamaged Clean the sensor (do not use compressed air) and if it is damaged replace it

X

18 Open the gas isolator cock reconnect the product to the mains and switch it on X X

19If the automatic purging programme does not start open the service valves fill the productor the heating installation to 01-02 MPa10-20 bar (depending on the static height of theheating installation) and manually start the purging programme P07

X

20Perform a test operation of the product and heating installation including hot water generation(if available) and purge the system once more if necessary

X X

21 Check the CO₂ content (the air ratio) of the product again X

22Ensure that no gas flue gas water or condensate is leaking from the product Restore leak-tightness if necessary

X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 40: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

40 Installation and maintenance instructions Ultimate 3 0020239566_01

H Opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 41: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) Dimensions D E F and G

These clearances may be reduced to 25 mm without affecting the performance of the boiler In order to ensure that the con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 42: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

42 Installation and maintenance instructions Ultimate 3 0020239566_01

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 43: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 43

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 44: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

44 Installation and maintenance instructions Ultimate 3 0020239566_01

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 45: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 45

J Combustion chart

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs part of the installation process especially where a flue has been fitted by persons other than the boiler installer visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg Gas Safe Technical Bulletin TB008)The flue gas analyser should be of the correct type as specified by BS 7967

Prior to its use the flue gas analyser should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser

Check and zero the analyser IN FRESH AIR as per analyser manufacturerrsquos instructions

NOTETHE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING CONTACT WITH THE MANUFACTURER

If any such adjustment is recommended and further checking of the boiler is required the

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - where no air inlet test point is provided then a flue integrity check

with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the ldquoPrior to CO

and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 ge 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno further actions required

Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed

Complete Benchmark Checklist recording CO and combustion ratio readings as required

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 ge 206

andCO2 lt 02

Check all seals around the appliance burner internal flue seals door and case seals

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED IF

COMMISSIONING CANNOT BE FULLY COMPLETED THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN ACCORDANCE WITH THE GSIUR

NOTE Check and record CO and combustion ratio at both max and min rate before contacting the

manufacturer

NO

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 46: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

46 Installation and maintenance instructions Ultimate 3 0020239566_01

K Lengths of the airflue pipe

Length of the C13 type airflue pipe

C13 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 6 m le 19 m

Length of the C33 type airflue pipe

C33 type flue pipe

Dia 60100 (L) Dia 80125 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m le 25 m

ULTIMATE 3 35c le 10 m le 19 m

Length of the C43 type airflue pipe

C43 type flue pipe

Dia 60100 (L)

Lengthoftheairfluepipe

ULTIMATE 3 30c le 10 m

ULTIMATE 3 35c le 10 m

L Technical data

Technical data ndash Heating

ULTIMATE 330c

ULTIMATE 335c

Maximum heating flow temperat-ure (default setting ndash D71)

75 75

Max range of the flow temperat-ure regulation

10 hellip 80 10 hellip 80

Safety discharge of expansionrelief valve

03 MPa

(30 bar)

03 MPa

(30 bar)

Maximum operating pressure 025 MPa

(250 bar)

025 MPa

(250 bar)

Nominal water flow (ΔT = 20 K) 1085 lh 1089 lh

Nominal water flow (ΔT = 30 K) 723 lh 726 lh

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

255 lh 255 lh

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass default setting)

0022 MPa

(0220 bar)

0025 MPa

(0250 bar)

ΔP heating at nominal flow (ΔT =20 K) ndash (bypass closed)

0022 MPa

(0220 bar)

0026 MPa

(0260 bar)

Technical data ndash G20 powerloading G20

ULTIMATE 330c

ULTIMATE 335c

Maximum heat output (default set-ting ndash d00)

20 kW 25 kW

Effective output range (P) at5030 degC

63 hellip 265 kW 74 hellip 265 kW

Effective output range (P) at8060 degC

6 hellip 252 kW 70 hellip 253 kW

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 47: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

0020239566_01 Ultimate 3 Installation and maintenance instructions 47

ULTIMATE 330c

ULTIMATE 335c

Hot water heat output range (P) 6 hellip 30 kW 7 hellip 35 kW

Maximum heat input ndash heating (Qmax)

255 kW 255 kW

Minimum heat input ndash heating (Qmin)

61 kW 71 kW

Maximum heat input ndash hot water(Q max)

306 kW 357 kW

Minimum heat input ndash hot water (Qmin)

61 kW 71 kW

Technical data ndash Domestic hot water

ULTIMATE 330c

ULTIMATE 335c

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

145 lmin 168 lmin

Continuous flow rate (ΔT = 35 K) 746 lh 864 lh

Specific flow rate (ΔT = 35 K) 124 lmin 144 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

Temperature range 35 hellip 60 35 hellip 60

Flow rate limiter 10 lmin 12 lmin

Technical data ndash General

ULTIMATE 330c

ULTIMATE 335c

Diameter of the gas pipe 12 inch 12 inch

Diameter of the heating pipe 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm

Condensed water discharge pipe(min)

215 mm 215 mm

G20 gas supply pressure 20 mbar 20 mbar

Gas flow at P max ndash hot water(G20)

32 msup3h 38 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646

Smoke mass flow in heating modeat P min

280 gs 326 gs

Smoke mass flow in heating modeat P max

115 gs 115 gs

Smoke mass flow in hot waterhandling mode at P max

138 gs 161 gs

Released system types C13 C33 C43C53

C13 C33 C43C53

Nominal efficiency at 8060 degC 988 993

Nominal efficiency at 5030 degC 104 104

Nominal efficiency in partial loadoperation (30) at 4030 degC

1097 1099

NOx class 5 5

Product dimensions width 418 mm 418 mm

Product dimensions depth 300 mm 300 mm

Product dimensions height 740 mm 740 mm

Net weight 326 kg 327 kg

Weight when filled with water 371 kg 372 kg

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 48: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Appendix

48 Installation and maintenance instructions Ultimate 3 0020239566_01

Technical data ndash Electrics

ULTIMATE 330c

ULTIMATE 335c

Electric connection 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V

Max power consumption 110 W 120 W

Standby electrical power con-sumption

2 W 3 W

Level of protection IPX4D IPX4D

Note

The lowest nominal heat output may be higher than the value in the technical data depending on the design of thesystem and the current operating status

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 49: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

Index

0020239566_01 Ultimate 3 Installation and maintenance instructions 49

Index

AAirflue pipe installed 5Article number 7BBurner anti-cycling time 20CCalling up the fault memory 25CE label 8Check programmes 30

Using 15Checking the burner 23Checking the pre-charge pressure of the expansionvessel 25Cleaning the condensate siphon 24Cleaning the heat exchanger 23Clearance 9CO₂ content

Checking 19 21Combustion air 6Competent person 4Completing inspection work 25Completing maintenance work 25Completing repair work 29Completing repair work 29Condensate drain pipework 12Condensate siphon

Filling 17Controller 14Controlling the bypass 20Corrosion 5ndash6DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 14Documents 7Draining the product 25EElectricity 5Expansion relief valve 28FFault codes 25Fault symbol 15Flow rate-pressure curves 20Flow sensor 29Flue gas route 5Front casing closed 5Frost 6GGas connection value 17HHanding over to the operator 21IIdentification plate 7If you smell gas 4Inspection work 21 39Installation site 5ndash6Intended use 4MMains connection 13

Maintenance work 21 39PPower supply 13Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump 20Pump head 27Pump output

Setting 20QQualification 4RRegulations 6Removing the air intake pipe 22Removing the burner 22Removing the flue gas pipe 22Removing the gas-air mixture unit 22Removing the ignition transformer 22Removing the side section 10Replacing the burner 26Replacing the expansion vessel 27Replacing the gas valve 26Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 27Resetting the burner anti-cycling time 20SSafety device 5Schematic drawing 5Serial number 7Setting the burner anti-cycling time 20Spare parts 21Switching on the product 17TTool 6Transport 5Transporting 8Treating the heating water 15UUnloading the box 8Unpacking the product 8Using

Check programmes 15Diagnostics codes 14

VVoltage 5WWeight 9

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W
Page 50: Installationandmain- tenanceinstructions · 1Safety 4 InstallationandmaintenanceinstructionsUltimate30020239566_01 1 Safety 1.1 Action-relatedwarnings Classificationofaction-relatedwarnings

The energy you need

ManufacturersupplierGlow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JT

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020239566_01 ‒ 10102016

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury during transport due to a high product weight
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of corrosion damage due to unsuitable combustion and room air
      • 1412 Risk of material damage caused by frost
      • 1413 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Applicability of the instructions
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Serial number
                • 33 Information on the identification plate
                • 34 Functional elements Combination unit
                • 35 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Clearance from combustible components
                        • 47 Using the installation template
                        • 48 Wall-mounting the product
                        • 49 Removinginstalling the front casing
                          • 491 Removing the front casing
                          • 492 Fitting the front panel
                            • 410 Removinginstalling the side section
                              • 4101 Removing the side section
                              • 4102 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain line for the expansion relief valve
                                    • 54 Connecting the condensate drain pipework
                                    • 55 Connecting the drain cock
                                    • 56 Electrical installation
                                      • 561 Opening and closing the electronics box
                                      • 562 Cable route
                                      • 563 Carrying out the wiring
                                      • 564 Establishing the power supply
                                      • 565 Connecting controllers to the electronic system
                                          • 6 Operation
                                            • 61 Using diagnostics codes
                                              • 611 Activating diagnostics codes
                                              • 612 Setting a diagnostics code
                                                • 62 Displaying the status codes
                                                  • 621 Activating the status codes display
                                                    • 63 Using check programmes
                                                      • 631 Calling up the check programmes
                                                      • 632 Displaying the pressure and temperature of the heating during a check programme
                                                          • 7 Start-up
                                                            • 71 Carrying out the initial start-up
                                                            • 72 Checking the factory setting
                                                            • 73 Checking and treating the heating waterfilling and supplementary water
                                                            • 74 Avoiding danger arising from insufficient water pressure
                                                            • 75 Switching on the product
                                                            • 76 Filling and purging the heating installation
                                                            • 77 Filling the condensate siphon
                                                            • 78 Filling the hot water circuit
                                                            • 79 Checking and adjusting the gas ratio setting
                                                              • 791 Checking the gas flow rate
                                                              • 792 Checking the gas connection pressure (gas flow pressure)
                                                              • 793 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                              • 794 Thoroughly flushing the heating installation (hot)
                                                              • 795 Checking the CO₂ content
                                                                • 710 Checking leak-tightness
                                                                  • 7101 Checking the heating mode
                                                                  • 7102 Checking the hot water generation
                                                                      • 8 Adapting the unit to the heating installation
                                                                        • 81 Burner anti-cycling time
                                                                          • 811 Setting the maximum burner anti-cycling time
                                                                          • 812 Resetting the remaining burner anti-cycling time
                                                                            • 82 Setting the pump output
                                                                            • 83 Setting the bypass
                                                                              • 9 Adjusting the hot water temperature
                                                                                • 91 Setting the hot water temperature
                                                                                  • 10 Handing the product over to the operator
                                                                                  • 11 Inspection and maintenance
                                                                                    • 111 Observing inspection and maintenance intervals
                                                                                    • 112 Procuring spare parts
                                                                                    • 113 Checking the CO₂ content
                                                                                    • 114 Setting the CO₂ content
                                                                                    • 115 Removing the gas-air mixture unit
                                                                                    • 116 Cleaning the heat exchanger
                                                                                    • 117 Checking the burner
                                                                                    • 118 Checking the ignition electrode
                                                                                    • 119 Cleaning the condensate tray
                                                                                    • 1110 Cleaning the condensate siphon
                                                                                    • 1111 Cleaning the filter in the cold water inlet
                                                                                    • 1112 Cleaning the heating filter
                                                                                    • 1113 Installing the gas-air mixture unit
                                                                                    • 1114 Draining the product
                                                                                    • 1115 Checking the pre-charge pressure of the expansion vessel
                                                                                    • 1116 Completing inspection and maintenance work
                                                                                      • 12 Troubleshooting
                                                                                        • 121 Rectifying faults
                                                                                        • 122 Calling up the fault memory
                                                                                        • 123 Deleting the fault memory
                                                                                        • 124 Resetting parameters to factory settings
                                                                                        • 125 Preparing the repair work
                                                                                        • 126 Replacing defective components
                                                                                          • 1261 Replacing the burner
                                                                                          • 1262 Replacing the gas-air mixture unit
                                                                                          • 1263 Replacing the gas valve
                                                                                          • 1264 Replacing the heat exchanger
                                                                                          • 1265 Replacing the pump head
                                                                                          • 1266 Replacing the expansion vessel
                                                                                          • 1267 Replacing the main PCB
                                                                                          • 1268 Replacing the PCB for the user interface
                                                                                          • 1269 Replacing the expansion relief valve
                                                                                          • 12610 Replacing the flow sensor
                                                                                          • 12611 Replace the pressure sensor
                                                                                            • 127 Completing repair work
                                                                                              • 13 Decommissioning the product
                                                                                              • 14 Customer service
                                                                                              • Appendix
                                                                                                • A Check programmes ndash Overview
                                                                                                • B Overview of diagnostics codes
                                                                                                • C Status codes ndash Overview
                                                                                                • D Overview of fault codes
                                                                                                • E Connection diagram Combination unit
                                                                                                • F Connection diagram Combination unit (35 kW)
                                                                                                • G Inspection and maintenance work ndash Overview
                                                                                                • H Opening in the airflue pipe
                                                                                                  • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                  • H2 Horizontal terminal positioning
                                                                                                    • I Commissioning Checklist
                                                                                                    • J Combustion chart
                                                                                                    • K Lengths of the airflue pipe
                                                                                                    • L Technical data
                                                                                                      • Index
                                                                                                        • A
                                                                                                        • B
                                                                                                        • C
                                                                                                        • D
                                                                                                        • E
                                                                                                        • F
                                                                                                        • G
                                                                                                        • H
                                                                                                        • I
                                                                                                        • M
                                                                                                        • P
                                                                                                        • Q
                                                                                                        • R
                                                                                                        • S
                                                                                                        • T
                                                                                                        • U
                                                                                                        • V
                                                                                                        • W