Installation and Servicing Condensing Boilers/Flexicom hx 12 hx G.C.No. 41-315-28 15 hx G.C.No. 41-315-29 18 hx G.C.No. 41-315-42 24 hx G.C.No. 41-315-61 30 hx G.C.No. 41-315-67 35 hx G.C.No.
Guarantee Registration Thank you for installing a new Glow-worm appliance in your home. Glow-worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive Guarantee. This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture, whichever is the shorter, for parts and labour.
TABLE OF CONTENTS These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts and Spares. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to the user on completion of the installation.
INTRODUCTION WARNINGS Gas Leak or Fault Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking, blowlamps, hot air guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows,ventilate the area. Sheet Metal Parts This boiler contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges.
INTRODUCTION CE Mark Gas Supply This boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels. Type test for purposes of Regulation 5 certified by: Notified body 0087. Product/production certified by: Notified body 0086. The CE mark on this appliance shows compliance with: 1.
INTRODUCTION Boiler Design Boiler Design Condensate Drain These boilers are designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect cylinder. Once the controls are set the boiler operates automatically. A plastic drain pipe must be fitted to allow discharge of condensate to a drain. Condensate should, if possible, be discharged into the internal household draining system.
TECHNICAL DATA 1 Boiler Specification 14730 0020107230_04 - 12/14 - Glow-worm -7-
INSTALLATION 13938 13937 Diagram 2.2 2 Boiler Dimensions and Hydraulic Schematic All dimensions are given in millimetres (except as noted). The general arrangment of the boiler is shown in diagram 2.1. and the hydraulic and gas schematic, diagram 2.2. The data label is positioned on the front of the inner casing panel. Diagram 2.
3 Boiler Location, Clearances and Ventilation 12792 INSTALLATION 3.1 Location This boiler is not suitable for outdoor installation. This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements. This boiler is suitable for installation in bathroom zones 2 and 3. In GB this is the current I.E.E. WIRING REGULATIONS and BUILDING REGULATIONS.
INSTALLATION 4 Evacuation of Combustion Gas 4.1 Regulation Only flue accessories supplied by Glow-worm must be used. Different flue outlet configurations can be carried out. • Consult your supplier for more information about the other possibilities and associated accessories. 44 mm/m H* and J* See diagram 4.2. These dimensions comply with the building regulations, but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions.
INSTALLATION Diagram 4.
INSTALLATION 4.2 Flue configuration description 4.2.1 Horizontal concentric flue Ø 60/100 mm or Ø 80/125 mm (C13 type installation) a Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m. 4.2.2 Telescopic direct rear flue Ø 60/100 mm Ø 60/100 mm If the terminal is at less than 1.80 m from the ground, you must install a terminal protection kit. L Ø 60/100 mm L 1 63 Type Max length Ø 60/100 512 mm 4.2.
INSTALLATION 4.2.4 Multiple boiler chimney flue Ø 60/100 mm (C43 type installation) The flue connecting from the appliance to the flue system must be supplied from the manufacturer of the boiler.
INSTALLATION 14401 5 Water Systems - General This boiler is designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect vented or unvented cylinder. 5.2 Draining Points Draining taps must be provided at all low points of the system, which will allow the entire system to be drained. Draining taps shall be to the current issue of BS2879. 5.
INSTALLATION • Where possible keep the existing boiler/circulating pump in place when flushing the system 5.6.2 Flushing the system • Fill the system with cold water and check for leaks. • Open all drain cocks and drain the system. • Close drain cocks and add a suitable flushing agent (cleaner) compatible with Aluminium at the correct strength for the system conditions in accordance with the manufacturer’s instructions.
INSTALLATION Water System - Domestic Hot Water Water System - Open (Vented) Central Heating System 5.7 Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE The domestic hot water cylinder must be of the double feed fully indirect coil type. 5.8 Unvented DHW System The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated at a maximum height of 27 metres (90ft) above the boiler. The cold feed must be 15mm minimum size.
INSTALLATION Water System - Sealed Central Heating System 5.12 Sealed Water Systems The installation must comply with the appropriate requirements of the current issue of BS4814, BS5449, BS6759, BS6798 and BS7074 Part 1 and 2. See diagram 5.4 for a suggested layout. 5.13 Safety Valve A diaphragm type expansion vessel, conforming to the current issue of BS4814 (see also BS7074 Part 1 and 2) must be connected at a point close to the inlet side of the circulating pump, see the diagrammatic layout, diagram 5.
INSTALLATION A pressure gauge with a set pointer and covering at least 0 to 4 bar (0 to 60 lb/in2) shall be fitted permanently to the system in a position where it can be seen when filling the system. 11680 5.15 Pressure Gauge 5.
INSTALLATION 14805 6 Installation Preparation 6.1 Appliance Pack Please check the contents of packs as shown in diagram 6.1. The packs are located in the top polystyrene packing. Remove the carton sleeve and top pack then lift the boiler and its polystyrene base support out of the lower pack. 6.2 Site Requirements The boiler mounting wall should be suitable for the weight of the appliance and be true and flat.
7 Boiler Fixing 7.1 Wall Hanging Bracket 14806 INSTALLATION The Wall Hanging Bracket is supplied in the main boiler packaging. Reposition the wall template over the flue hole and mark the position of the fixing holes for the hanging bracket, see diagram 7.1. NOTE: Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable. Drill fixing holes and insert suitable wall plugs.
INSTALLATION 8.2 Water Connections 14507 Before connection check the supply of local gas. The gas supply connection is below the boiler, see diagram 8.1. The whole of the gas installation, including the meter, should be inspected, tested for tghtness and purged in accordance with the current issue of BS6891 and in IE the current edition of I.S.813 “Domestic Gas Installations”. Provision is made for the water connections to be made from above the boiler, see diagram 8.1.
9 Condensate Connections 9.1 Condensate Drain Connection 14508 INSTALLATION The condensate drain connection, is positioned below the boiler as shown in diagram 9.1. To discharge condensate to a drain, the drain pipe should have a fall of a least 44mm/metre (2.5°) away from the boiler. Condensate should, if possible be discharged into the household internal drainage system.
INSTALLATION 15826 Diagram 9.
INSTALLATION 13905 10 Electrical Connection WARNING: This appliance must be earthed. ● This appliance must be wired in accordance with these instructions. Any fault arising from incorrect wiring cannot be put right under the terms of the Glow-worm guarantee. ● All system components must be of an approved type. Electrical components have been tested to meet the equivalent requirements of the BEAB. ● Do not interrupt the mains supply with a time switch or programmer.
INSTALLATION 13906 10.3 Electrical Cartridge Securing Close the cartridge and secure with the previously removed screw. Push the electrical cartridge into the interface housing on completion of the wiring, see diagram 10.3. Secure with the two cartridge retaining screws provided in the cartridge body. 10.4 Electrical Connections - Testing Carry out preliminary electrical system checks as below: 1. Test insulation resistance to earth of mains cables. 2.
INSTALLATION 14513 Diagram 11.2 Commissioning should only be carried out by a competent person approved at the time by the Health and Safety Executive. 11.4 Initial Lighting NOTE: Ensure that initial lighting of the appliance takes place with the front casing door removed and the control box lowered. Initially run the pump to ensure all air has been vented from the system.
INSTALLATION 11.7 Heating System Operational Gas Inlet Pressure With ALL other gas appliances operating, check the operational supply pressure at the gas service isolation valve test point, see diagram 11.1. The nominal supply pressure for Natural Gas (G20) is 20mbar. Turn the taps and appliances off, then disconnect the pressure gauge. Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar. NOTE: The BURNER PRESSURE cannot be measured.
MAINTENANCE IMPORTANT NOTES: 1. 2. 3. 4. 5. 6. To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough. It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive.
MAINTENANCE Before commencing with a service or replacement of parts. The boiler should be isolated from the electrical and gas supplies. 14291 ● Rotate the “throttle”(anti-clockwise to increase), to the required CO2, refer to diagram 12.4 and the “SETTING” column in the table. ● Exit the forced rate function, press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display. Now proceed to check the minimum rate adjustment. 2.
MAINTENANCE NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component. 14406 12.4 Spark Electrode Ease the securing clips away from the sump to release the retaining catch then push the flue hood up to disengage from the sump, see diagram 12.5. To remove, swivel flue hood 90o and pull down and out, see diagram 12.5. Check seal for wear or damage and replace if necessary. IMPORTANT: Do not allow fixings, nuts, screws, etc.
MAINTENANCE 14409 14079 Diagram 12.9 14081 Diagram 12.7 13128 Diagram 12.10 14288 Diagram 12.8 Diagram 12.
MAINTENANCE 12.6. Heat Exchanger 12.8 Casing panel seal check NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component. NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component. Remove loose debris from inside the heat exchanger using a soft brush and vacuum cleaner. Check the condition of the seal and replace if worn or damaged.
MAINTENANCE 13.1 Preliminary fault finding Diagram 13.1 13845 The following checks should be performed before proceeding onto specific diagnostics: • Check the external electrical supply to the boiler is on and a supply of 230V is present at the ‘L’ and ‘N’ terminals at the installer interface. For access remove and open the electrical cartridge, see diagrams 10.3. and 10.1. Test at the ‘L’ and ‘N’ terminals on the installer interface, refer to diagrams 10.2 and 13.4.
MAINTENANCE 13917 Diagram 13.
MAINTENANCE 13012 Diagram 13.
MAINTENANCE In all circumstances press the reset button to clear the fault. If the fault persists, consult the table below. FAULT CODES 14029 Diagram 13.
MAINTENANCE State list - To access the state lists the ‘-’ button must be pressed for longer than 5 seconds until it begins to flash ‘S’ and then a number to indicate the state. The state numbers are given below. 14029 STATE LISTS 13131 Diagram 13.
MAINTENANCE To enter the diagnostics menu follow the procedure below:Press and hold the ‘MODE’ and ‘+’ buttons for approx 5 seconds until the screen changes. Use the ‘+’ or ‘-’ button to select the number 96, this is the password. Hold the ‘MODE’ for approx 5 seconds when 96 is selected, when the screen changes release the button. The screen will flash between ‘L1’ and a number. ‘L1’ indicates you have level 1 access, the number indicates the diagnostic number below.
MAINTENANCE 14 Replacement of Parts 14.1 General Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety Executive. Replacement parts that have associated components that need replacing on removal, ie. ‘O’ ring seals, gasket, etc; will be supplied and should be fitted. Before replacing any parts the boiler should be isolated from the mains electric supply and the gas should be turned off at the gas service isolation valve on the boiler, see diagram 14.1.
MAINTENANCE For access, refer to section 14.1. 12964 14.10 Burner Remove igniter unit, flue hood, fan and gas valve assembly and spark electrode lead, refer to relevant sections. Remove the flanged nuts and studs that secure the burner, note that two studs at the rear also hold the fan clamping bracket, see diagram 12.10. NOTE: The burner gasket should be inspected but will not need replacing unless there are signs of wear or damage. IMPORTANT: Do not allow fixings, nuts, screws, etc.
MAINTENANCE For access, refer to section 14.1. Refer to diagram 14.3. Remove the electrical connections from the thermistor. Remove the retaining clip from the return pipe. Remove the thermistor from the retaining clip. Note that the polarity of the wiring to thermistor is unimportant. 14379 14.13 Heating Return Thermistor 14.14 Heat Exchanger For access, refer to section 14.1. Drain down the boiler heating circuit Remove the silencer front Pull forwards to remove.
MAINTENANCE Remove the heat exchanger Remove the burner Undo the screws securing the flanged elbow on the top right hand side of the heat exchanger and remove the retaining clip from the flanged elbow, see diagram 14 5. Remove the six flanged nuts and two studs that secure the burner, note that the two studs also hold the fan clamping bracket, see diagram 14.7. Remove retaining clip from the flanged elbow on the bottom of the heat exchanger, see diagram 14.4.
MAINTENANCE 14.15 Casing Seal 14.18 Fuse - Main PCB - Control Box Refer to Section 12.8. For access, refer to section 14.16. The fuse is located at the top left hand corner of the main PCB, see diagram 14.8. 14.16 Access to User interface and Main PCB 14.19 Installer Interface Electrical Cartridge For access, refer to section 14.1. Remove the Installer Interface securing screw accessed from beneath the boiler. Hinge down the control box and unclip the rear cover to gain access.
MAINTENANCE 15 Spare Parts Key No. Part No. Description GC No 1 0020020734 Fan H42723 2 0020020763 Igniter unit H42773 3 0020020781 Heating flow & return thermistor (2) H42792 4 0020020735 Gas valve 12hx - 30hx H42724 4 0020059600 Gas valve 35hx H69002 5 0020020731 Spark Electrode H42720 6 0020020728 Burner 12hx - 30hx H42718 6 0020059601 Burner 35hx H68999 7 0020023826 User interface H42784 8 0020023825 Main P.C.B. H42783 13013 Diagram 15.
MAINTENANCE 16 Manual handling IMPORTANT. With regards to the Manual Handling Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a one man lift. General recommendations when handling Clear the route before attempting the lift. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. Do not twist – reposition feet instead. If 2 persons performing lift, ensure co-ordinated movements during lift.
Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the PDQXIDFWXUHUV LQVWUXFWLRQV DQG WKH GDWD ¿HOGV RQ WKH FRPPLVVLRQLQJ FKHFNOLVW completed in full.
GAS BOILER SYSTEM COMMISSIONING CHECKLIST 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.
SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
PRIOR TO CO AND COMBUSTION RATIO CHECK The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas supply pressure/rate checked as required prior to commissioning. As 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 manufacturer’s max.
0020107230_04 - 12/14 GLOW-WORM Nottingham Road, Belper, Derbyshire. DE56 1JT www.glow-worm.co.uk © These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with the manufacturer’s written consent.
