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Installation and main-tenance instructionsUltimate 3
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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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
Recommended