Glow-worm Flexicom 12hx Installation And Servicing
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Glow-worm Flexicom 12hx Installation And Servicing

High efficiency condensing boilers
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INSTALLATION AND SERVICING

12hx
G.C. No. 41-315-28
15hx
G.C. No. 41-315-29
18hx
G.C. No. 41-315-42
24hx
G.C. No. 41-315-61
High Efficiency
Condensing
Boilers
Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT
Flexicom
www.glow-worm.co.uk
1
2000225262-04 02.06

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  • Page 1: Installation And Servicing

    2000225262-04 02.06 INSTALLATION AND SERVICING Flexicom 12hx G.C. No. 41-315-28 15hx G.C. No. 41-315-29 18hx G.C. No. 41-315-42 24hx G.C. No. 41-315-61 High Efficiency Condensing Boilers Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT www.glow-worm.co.uk...

  • Page 2: Guarantee Registration

    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.

  • Page 3: Table Of Contents

    The instructions consist of two parts, Installation and Servicing Instructions. The instruc- tions 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.

  • Page 4: Warnings

    External wiring must be correctly earthed, polarised and in ance. It is, therefore, important that no alteration is made to accordance with the relevant standards. the boiler, without permission, in writing, by Glow-worm. In GB this is BS 7671. Any alteration not approved by Glow-worm, could invalidate In IE this is the current edition of I.S.813 “Domestic Gas Instal-...

  • Page 5: General Information

    General Information Clearances General Note If fixtures are positioned close to the boiler, space must be Once the controls are set the boiler operates automatically. left as shown in diagram 2.1. Please read these instructions and follow them carefully for the correct installation and economical use of your boiler.

  • Page 6: Appliance Safety Devices

    Glow-worm. of care imposed on the owner of the property by the current is- If a part is required contact Glow-worm’s own service organisa- sue of the Gas Safety (Installation and Use) Regulations, Sec- tion using the telephone number on the inside front cover of tion 35.

  • Page 7: Technical Information

    1 Technical Information FLUE BOILER 246.5 Condense Drain Point Diagram 1.1 1.1 IMPORTANT The Current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be The boiler is supplied in one carton, which includes the appli- made to the relevant British Standard Code of Practice. ance fixings and fittings, see diagram 5.1.

  • Page 8: Technical Data

    1 Technical Information 1.3 Technical Data BOILER SPECIFICATION 12hx to 24hx All dimensions are given in millimetres (except as noted). See diagrams 1.1 and 1.2. Lift weight 25kg (55Ib) The data label is positioned on the base of the boiler. Total weight (installed) 28kg (62Ib) Gas connection Ø...

  • Page 9: Boiler Location And Ventilation

    If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from the local gas undertaking or Glow-worm. 2.4 Room Ventilation The boiler is room sealed so a permanent air vent is not + A removable compartment door can be placed required.

  • Page 10: Flue Options & Terminal Clearances 3

    flue Ø60/100 - Part No. 2000460485 Flue support clips (3), concentric flue Ø60/100- Part No. A2043900 Additional accessories are available. See Glow-worm “Flexicom Range Guide” for configurations available. Vertical Flue Vertical Flue Adapter, concentric flue Ø60/100 Part. No. A2024600 Vertical flue terminal kit, concentric flue Ø60/100...

  • Page 11: Flue Options

    3 Flue Options and Terminal Clearances 3.1 Flue Options There are various flue options to choose from as illustrated in diagram 3.1. The flue lengths and installation are described in section 9. 3.2 Flue Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 3.2.

  • Page 12: Water System

    4 Water System 4.1 Safety Valve 4.4 Bypass A safety valve need not be fitted to an open-vented system. A bypass is not required on the central heating system unless the system controls could allow the boiler and pump to oper- ate when there is no flow.

  • Page 13: Domestic Hot Water System

    4 Water System 4.9 Draining Points Draining taps must be provided at the lowest points of the system, which will allow the entire system to be drained. A Draining point for the appliance is provided at the position shown in diagram 4.2. 4.10 Domestic Hot Water System - unvented General - All domestic hot water circuits, connections, fittings...

  • Page 14: Safety Valve

    4 Water System 4.12 Safety Valve SUPPLY A safety valve must be fitted to a sealed system. PIPE It shall be preset, non-adjustable with a lift pressure of 3 bar, incorporating seating of a resilient material, a test device and a connection for drain.

  • Page 15: Installation Preparation

    5 Installation Preparation 5.1 Appliance Fixings and Fittings 5.2 Wall Template IMPORTANT: With regards to the Health and Safety Manual Take the wall template from the documentation pack located Handling requirements, the following lift operation is deemed within the top polystyrene packing and place in the desired to be a one person lift, refer to section 16 Manual Handling.

  • Page 16: Boiler Fixing 6

    6 Boiler Fixing 6.1 Hanging Bracket Reposition the wall template over the flue hole and mark the position of the fixing holes for the hanging bracket, see diagram 6.1. NOTE: Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable.

  • Page 17: Gas/Water & Appliance Connection

    7 Gas / Water & Appliance Connection 7.1 Gas Connection Before connection check the supply of local gas. The gas supply can be connected from below, see diagram 7.1. or through the wall at the rear of the boiler. Refer also to section 1.2 and 1.3. The whole of the gas installation, including the meter, should be inspected, tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition...

  • Page 18: Condensate Connection

    8 Condensate Connections 8.1 Condensate Drain Connection For condensate drain connection, see diagram 8.1. 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.

  • Page 19: Condensate Connections

    8 Condensate Connections INTERNAL SOIL EXTERNAL SOIL AND VENT STACK AND VENT STACK BOILER BOILER EXTERNAL MAX. 3M MIN. DIA. 21mm MIN. DIA. 21mm NO RESTRICTION NO RESTRICTION ON LENGTH ON LENGTH Internal Soil and Vent Pipe External Soil and Vent Pipe or Rainwater Pipe SINK (CONSTITUTES BOILER...

  • Page 20: Flue Preparation And Installation

    9 Flue Preparation and Installation 9.1 Top Horizontal Rear flue - Telescopic Part No. A2043600. Refer to diagram 9.1 for kit contents. 9.2 Flue Length If a wall thickness of 232 min. to 437 max. is available the Top horizontal rear flue - telescopic can be used without extensions.
  • Page 21 9 Flue Preparation and Installation Diagram 9.7 Diagram 9.4 9.5 Top Horizontal Rear flue - Standard Part No. A2043400. Refer to diagram 9.8 for kit contents. 9.6 Flue Length If a wall thickness of 75 min. to 507 max. is available the Top horizontal rear flue - standard can be used without extensions.
  • Page 22 9 Flue Preparation and Installation The cut ducts must be de-burred and all filings and debris removed. Insert the flue duct into the air duct terminal assembly, remembering to engage the catch within the terminal. NOTE: If you require to lubricate the seals to ease installation, please do not use a mineral oil based grease, we would recommend the use of water.
  • Page 23 9 Flue Preparation and Installation 9.8 Top Horizontal Side flue - Telescopic Part No. A2043600. Refer to diagram 9.1 for kit contents. 9.9 Flue Length The maximum permissable horizontal flue length is 8 metres plus the Top horizontal side flue - telescopic. This can be achieved by the use of the extensions, however, for every or 45 elbows used the flue length MUST be reduced by 1...
  • Page 24 9 Flue Preparation and Installation 9.12 Top Horizontal Side flue - Standard Part No. A2043400. Refer to diagram 9.8 for kit contents. 9.13 Flue Length Remove the top flue outlet cover secured with four screws, see diagram 9.2. Temporarily fit the flue elbow, measure the distance from the outside wall to flue elbow.
  • Page 25 9 Flue Preparation and Installation 9.15 Rear flue - Telescopic Part No. A2043500. Refer to diagram 9.14 for kit 24 to 28 contents. 9.16 Flue Length Measure the distance from the outside wall to the inside wall face. This measurement must not exceed 512mm. if the dimension is less than 291mm DO NOT cut the flue, it can project to its maximum.
  • Page 26 9 Flue Preparation and Installation 9.18 Vertical flue The vertical flue system is available as an option where the boiler position does not permit the use of the top horizontal or rear flue system. The system is made up of accessories. The accessories include terminal assembly, bends 45º...

  • Page 27: Flue Terminal Installation

    9 Flue Preparation and Installation Flue Terminal Installation (a) Pitched Roof Fit the required pitched roof weather collar over the 150mm hole in the roof. Make good the tiling or slating around the collar incorporating the flashing of the weather collar. Position the angle cap over the weather collar in the correct orientation to attain the correct angle for your roof.
  • Page 28 9 Flue Preparation and Installation Diagram 9.21 Diagram 9.22...

  • Page 29: Terminal Position

    9 Flue Preparation and Installation 9.19 Twin flue The twin flue system is available as an option when the top horizontal, rear or vertical flue system is not appropriate. The system can provide an independent horizontal air inlet and flue outlet, horizontal air inlet and vertical flue outlet or vertical air inlet and flue outlet via a concentric terminal.
  • Page 30 9 Flue Preparation and Installation Horizontal Terminal Installation With due consideration to terminal clearances mentioned in Section 3.2 drill the one or two holes as required with a 90mm core drill. Push the horizontal terminal through the wall allowing approx. 100mm to protrude outside.
  • Page 31 9 Flue Preparation and Installation Diagram 9.25...
  • Page 32 For each 90 bend or 2 x 45 bends the maximum length of the Plume Management Kit must be reduced by 1m. For more information contact Glow-worm, refer to page 2. The Plume Management Kit is supplied with installation instructions. AIR BRICK...

  • Page 33: Electrical Connection

    Any fault arising from incorrect wiring cannot must be permanently fixed to a wall or a be put right under the terms of the Glow-worm guarantee. All system components must be of an approved type. sturdy support feature in a tidy manner.
  • Page 34 10 Electrical Connection REMOVAL AND REPLACEMENT OF INSTALLER INTERFACE AND CAP FLEXICOM OPEN VENT VIEW ON UNDERSIDE OF BOILER 230Vac SECURING FROST STAT SCREW 230Vac PUMP SYSTEM CONTROLS JUNCTION CABLE 3 AMP FUSE SECURING SECURING CLIP SCREW Diagram 10.1 DOUBLE POLE ISOLATOR 230Vac 50Hz...

  • Page 35: Commissioning

    11 Commissioning 11.7 Completion 11.1 Preliminaries - All Systems Adjust the boiler temperature control and any system controls A competent person in accordance with the current issue of to their required settings. In addition it is necessary to com- BS6798 should carry out commissioning. plete the “Benchmark”...

  • Page 36: Servicing

    12 Servicing Important Notes 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 PRESSURE year should be enough.
  • Page 37 12 Servicing Monitor the combustion reading and at min rate the read- ing should be 9.3% ± 0.5. If adjustment proves necessary then proceed as follows: Press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approxi- mately 5 seconds “Hi”...
  • Page 38 12 Servicing 12.3 Burner ELECTRICAL Disconnect the gas supply at the gas valve and electrical CONNECTIONS connections, see diagram 12.6. The Silencer (front) is a push fit, so there is no need for tools to remove or fit, see diagram 12.7. IGNITION LEAD Release the igniter unit support bracket, see diagram 12.8.
  • Page 39 12 Servicing Check the spark electrode gap is 4mm. Clean and adjust as necessary, diagram 12.11. FAN CLAMPING It should not be necessary to remove the spark electrode from BRACKET the burner during servicing. SECURING Remove the flanged nuts and studs that secure the burner, NUTS (6) note that two studs at the rear also hold the fan clamping bracket, see diagram 12.12.

  • Page 40: Fault Finding

    13 Fault Finding NOTE Before trying to operate the boiler make sure that : • All gas supply cocks are open and that the gas supply has been purged of air. • There is a permanent mains supply to the boiler. •...
  • Page 41 13 Fault Finding HEATING FLOW THERMISTOR CONTROL VALVE HEATING RETURN THERMISTOR IGNITER UNIT IGNITION ELECTRODE N L R F PUMP EXTERNAL CONTROLS 230V~50Hz MAINS SUPPLY MAIN CONTROL BOARD APPLIANCE INTERFACE BOARD FLEXICOM HX Diagram 13.1...
  • Page 42 13 Fault Finding START Is there anything displayed Is the power switched on? Switch the power on on the LCD? Check wires between main PCB and display Is the display flashing 'F'? Consult the Fault Table Initiate a CH demand. Does the boiler light? Does the display flash 'F' Successful ignition...
  • Page 43 13 Fault Finding In all circumstances press the reset button to clear the fault. If the fault persists, consult the table below. FAULT LISTS Diagram 13.3...
  • Page 44 13 Fault Finding 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. STATE LISTS Diagram 13.4...
  • Page 45 13 Fault Finding To enter the diagnostics menu follow the procedure below:- Press and hold the ‘ ’ 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 ‘ ’...

  • Page 46: Replacement Of Parts

    14 Replacement of Parts 14.1 General Replacement of parts must be carried out by a competent person. Before replacing any parts the boiler should be isolated from the mains electric supply and the gas should be turned off at PRESSURE the service cock on the boiler, see diagram 14.1.

  • Page 47: Spark Electrode

    14 Replacement of Parts 14.6 Flue Hood 14.10 Burner For access, refer to section 14.1. For access, refer to section 14.1. Pull the flue hood securing clips away from the flue hood Remove igniter unit, flue hood, fan and gas valve assembly sump and push flue hood up slightly towards flue hood top, and spark electrode lead, refer to relevant sections.
  • Page 48 14 Replacement of Parts 14.11 Condensate Trap For access, refer to section 14.1. Remove locating screw, see diagram 12.13. Disconnect the flexible condense drain pipe from the external plastic drain pipe beneath the boiler. Carefully pull the condensate trap down and forward so as not to spill its contents.
  • Page 49 14 Replacement of Parts 14.14 Heat Exchanger HEAT EXCHANGER For access, refer to section 14.1. SECURING (Flow pipe and burner removed) SCREW Remove silencer front, flue hood, gas valve / burner assem- bly, spark electrode lead, burner and condense trap. Drain the heat exchanger using the drain point on the right hand side of the heat exchanger, see diagram 14.4.
  • Page 50 14 Replacement of Parts 14.16 Access to User interface and Main RETAINING CLIPS FUSE For access, refer to section 14.1. Hinge down the control box and unclip the rear cover to gain access. Remove electrical connections from main PCB noting their positions for replacement.
  • Page 51 14 Replacement of Parts 14.17 Control Box CONTROL BOX SECURING For access, refer to section 14.1. REAR COVER SCREW Hinge down the control box and unclip the rear cover to gain access. HINGE Remove relevant electrical connections from main PCB and grommets from the control box.

  • Page 52: Spare Parts

    15 Spare Parts Key No. Part No. Description GC No 0020020734 XXXXXX 0020020763 Igniter unit XXXXXX 0020020781 Heating flow & return thermistor (2) XXXXXX 0020020735 Gas valve XXXXXX 0020020731 Spark Electrode XXXXXX 0020020728 Burner XXXXXX 0020023826 User interface XXXXXX 0020023825 Main P.C.B.

  • Page 53: Manual Handling

    16 Manual Handling IMPORTANT. to body as possible. Always use assistance if required. Dispose of With regards to the Manual Handling Opera- packaging in a responsible manner. Recommend wear suitable cut tions, 1992 Regulations, the following lift operation exceeds the resistant gloves with good grip to protect against sharp edges and recommended weight for a one man lift.
  • Page 56 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

This manual is also suitable for:

15hx18hx24hx

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