Glow-worm Flexicom 24cx Installation And Servicing Manual
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Glow-worm Flexicom 24cx Installation And Servicing Manual

High efficiency condensing combination boilers
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Flexicom

Installation and Servicing

24cx
G.C. No. 47-047-33
30cx
G.C. No. 47-047-34
35cx
G.C. No. 47-047-35
High Efficiency
Condensing Combination
Boilers
www.glow-worm.co.uk

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  • Page 1: Installation And Servicing

    Flexicom Installation and Servicing 24cx G.C. No. 47-047-33 30cx G.C. No. 47-047-34 35cx G.C. No. 47-047-35 High Efficiency Condensing Combination Boilers 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 and labour.

  • Page 3: 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.

  • Page 4: Warnings

    Glow- - Be physically capable worm. - Use safety clothing where appropriate, e.g. gloves, safety Any alteration not approved by Glow-worm, could invalidate footwear. the certification, boiler warranty and may also infringe the Ensure safe lifting techniques are used current issue of the statutory requirements.

  • Page 5: Gas Supply

    Statutory Requirements CE Mark Gas Supply This boiler meets the requirements of Statutory Instrument, The gas installation must be in accordance with the relevant No. 3083 The Boiler (Efficiency) Regulations, and therefore is standards. deemed to meet the requirements of Directive 92/42/EEC on In GB, this is BS6891.

  • Page 6: Boiler Design

    Once the blockage is removed the boiler should then restart. be any discharge from the pipe, isolate the boiler electrical supply and call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet.

  • Page 7: Boiler Specification

    1 Boiler Specification BOILER SPECIFICATION 24cx 30cx 35cx Lift weight 36kg (79Ib) 36kg (79Ib) 36kg (79lb) Total weight (installed) 41kg (90Ib) 41kg (90Ib) 41kg (90lb) Gas connection Ø O.D. 15mm. copper 15mm. copper 15mm. copper Heating and return connection Ø O.D. 22mm.

  • Page 8: Boiler Dimensions And Hydraulic Schematic

    2 Boiler Dimensions and Hydraulic Schematic 2.1 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.

  • Page 9: Boiler Location, Clearances 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 local gas undertaking or Glow-worm. 3.4 Combustible Material The boiler and flue are suitable for installation onto and...

  • Page 10: Flue Options And Terminal Clearances

    4 Flue Options and Terminal Clearances Ridge Tile Terminal Part No. A2043800 - Section 10, page 30 Plume Management Kit basic set, white, concentric flue (Ø60/100) - Part No. A2044100 for use with Part No. A2043400 and Part No. A2043600 - Section 10, page 36 Top horizontal standard flue (Ø60/100) Top horizontal telescopic flue (Ø60/100)

  • Page 11: Flue Terminal Position

    4 Flue Options and Terminal Clearances 4.1 Flue Options There are various flue options to choose from as illustrated in diagram 4.1. The flue lengths and installation are described in section 10. 4.2 Flue Terminal Position In GB the minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.2.

  • Page 12: Safety Valve

    5 Water System - Heating 5.1 General This boiler is designed for use as part of a sealed water central heating system with fully pumped circulation. The pump, expansion vessel and associated safety devices are all fitted within the boiler. 5.2 Safety Valve The safety valve is an integral part of the boiler and it cannot be adjusted.The pipe from the safety discharge valve must...
  • Page 13 5 Water System - Heating Diagram 5.4 Diagram 5.2 Diagram 5.3...

  • Page 14: Water System - Domestic Hot Water

    5 Water System - Domestic Hot Water 5.9 Water Pressure The minimum working pressure to obtain the maximum domestic flow is:- 24cx 1.0bar 30cx 1.0bar 35cx 1.0bar The maximum working pressure of the domestic hot water circuit is 10 bar. If the cold water supply pressure exceeds this, then a pressure-reducing valve must be fitted in the supply to the boiler.

  • Page 15: Installation Preparation

    6 Installation Preparation H - Boiler Securing Screw Diagram 6.1...

  • Page 16: Site Requirements

    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.

  • Page 17: Gas/Water Connections

    7 Gas / Water Connections 7.1 System connection Fit the Central Heating Isolation Valve handles and secure with screws provided. NOTE: The appliance may contain a small amount of water, place a water container beneath the boiler connections Fit the assembled Jig Plate to the Support Plate as shown in diagram 7.2.

  • Page 18: Boiler Fixing

    8 Boiler Fixing 8.1 Boiler Hanging IMPORTANT: With regards to the Manual Handling Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a one man lift, refer to section 17 Manual Handling. IMPORTANT: Direct Rear Flue only - The direct rear flue must be fitted before hanging the boiler, refer to sections 10.11 to 10.13, and the rear outlet cover plate should be removed.

  • Page 19: Safety Discharge Valve And Condensate Connections

    9 Safety Discharge Valve and Condensate Connections 9.1 Safety Discharge Valve Take the safety discharge pipe, supplied in the pipe pack and the union nut and seal, supplied in the loose items pack and fit as shown in diagram 9.1. This must be extended, using not less than 15mm o.d.
  • Page 20 9 Safety Discharge Valve and Condensate Connections Diagram 9.2...

  • Page 21: Flue Length Preparation And Installation

    10 Telescopic Flue - Length, Preparation and Installation 10.1 Flue Length Multiple Boiler Chimney Flue Length The maximum permissable horizontal flue length is 8 metres The flue length must be calculated and installed according to plus the flue terminal assembly, this can be achieved by use the relevant standards EN 13384-1 and 2 (C43 flue systems of the accessories, see diagram 10.3.
  • Page 22 10 Telescopic Flue - Length, Preparation and Installation Diagram 10.2 Diagram 10.3...
  • Page 23 10 Telescopic Flue - Length, Preparation and Installation 10.2 Horizontal Telescopic Flue - A2043600 Refer to diagram 10.2 for kit contents. 10.3 REAR Flue If a wall thickness is between 231mm min. to 441mm max. then the flue can be used without extensions. Remove the top flue outlet cover complete with resonator and discard, see diagram 10.4.
  • Page 24 10 Telescopic Flue - Length, Preparation and Installation 10.5 Flue Fitting IMPORTANT:- The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water. During the installation of the flue system, ensure that debris such as mortar, filings or swarf are cleared from the flue system before completion.
  • Page 25 10 Standard Flue - Length, Preparation and Installation 10.6 Flue Length Standard Horizontal Flue The maximum permissable horizontal flue length is 8 metres plus the flue terminal assembly, this can be achieved by use of the accessories, see diagram 10.13. However should additional 87.5º...
  • Page 26 10 Standard Flue - Length, Preparation and Installation Diagram 10.12 Diagram 10.13...
  • Page 27 10 Standard Flue - Length, Preparation and Installation 10.7 Standard Horizontal Flue - A2043400 Refer to diagram 10.12 for kit contents. 10.8 REAR Flue Remove the top flue outlet cover complete with resonator and discard, see diagram 10.4. Using these screws inserted into the same holes on the boiler, temporarily secure the flue elbow, measure the distance...
  • Page 28 10 Standard Flue - Length, Preparation and Installation 10.10 Flue Fitting IMPORTANT:- The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water. During the installation of the flue system, ensure that debris such as mortar, filings or swarf are cleared from the flue system before completion.
  • Page 29 10 Direct Rear Flue - Length, Preparation and Installation 10.11 Direct Rear flue - Telescopic Part No. A2043500. Refer to diagram 10.19 for kit contents. 10.12 Flue Length Measure the distance from the outside wall to the inside wall face. This measurement must not exceed 512mm (465mm if the upward piping kit is used).
  • Page 30 10 Vertical Flue - Length, Preparation and Installation 10.14 Vertical flue The terminal siting should be as shown in diagram 4.2. Measure the distance of flue length required for the The vertical flue system is available as an option where the installation.

  • Page 31: Flue Terminal Installation

    10 Vertical - Flue Length, Preparation and Installation such as mortar, filings or swarf are cleared from the flue system before completion. Long lengths of flues must be secured to the walls or ceilings they run against. Use at least one fixing bracket for every flue extension that is used.
  • Page 32 10 Vertical Flue - Length, Preparation and Installation Completion of Installation With the flue terminal positioned in the roof the length of the final pipe can be determined. If a telescopic length cannot be used, then a standard flue length can be cut to make the correct length.
  • Page 33 10 Twin Flue - Length, Preparation and Installation Secure long flue lengths (horizontal & vertical) to walls or ceiling at every joint or on straight flue runs at every joint and every metre flue run. Diagram 10.29...

  • Page 34: Terminal Position

    10 Twin Flue - Length, Preparation and Installation 10.15 Twin flue length The twin flue system is available as an option when the top horizontal 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 35: Installation Details

    10 Twin Flue - Length, Preparation and Installation Installation Details The parts available for a twin flue system installation are shown in diagram 10.30. Boiler Connection IMPORTANT: The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water.
  • Page 36 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. Refer to BS5546 or BS6798 for advice on disposal of boiler condensate.

  • Page 37: Electrical Connection

    ● 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.

  • Page 38: Commissioning

    11 Electrical Connection Diagram 11.4 Diagram 11.3 11.4 Electrical Cartridge Securing 11.5 Electrical Connections - Testing With the gas service isolation valve closed and with no Carry out preliminary electrical system checks as below: demand from any external controls, fit the electrical cartridge 1.

  • Page 39: Filling Domestic Water Circuit

    12 Commissioning 12.3 Filling Domestic Water Circuit 5. Open the two filling taps marked ‘D’ by rotating them through 90° to fill the heating system to a pressure of Fully open any valves in the domestic water supply to the 1.0bar.
  • Page 40 12 Commissioning MODE MODE Diagram 12.2 DO NOT operate the boiler without water. 12.7 Check the Gas Inlet Pressure & Gas Check that all external controls are calling for heat. Rate Set the Central Heating temperature and the Domestic Hot Water temperature to ON by pressing the MODE button The supply from the governed meter must be of adequate on the User Interface until it shows the appropriate symbol...

  • Page 41: Instruct The User

    12 Commissioning The appliance pump has two speeds and can be adjusted to Gas Rate suit the requirements of the system. Make sure that ALL other gas burning appliances and pilot The appliance has an inbuilt automatic adjustable bypass lights are off. valve.

  • Page 42: Servicing

    When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm. If any electrical connections have been disconnected and after their connection, checks to the earth continuity, polarity, short circuit and resistance to earth must be repeated using a suitable multimeter, as described in section 14.

  • Page 43: Combustion Ratio

    CO/CO2 ratio is acceptable. Advice can be sought from the Glow-worm Technical Helpline. 13.1 Servicing NOTE: If the Combustion CO2, CO/CO2 ratio & Gas rate checks did not require adjustment then it will not be necessary Diagram 13.4...

  • Page 44: Spark Electrode

    13 Servicing 13.2 Spark Electrode NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component. 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 13.5.
  • Page 45 13 Servicing ELECTRICAL SECURING CONNECTIONS SCREW (3) SECURING SUPPORT BRACKET IGNITION LEAD SPADE CONNECTOR IGNITER EARTH CONNECTION UNIT Diagram 13.9 VALVE TUBING ELECTRICAL PIPE CONNECTION (removed) Diagram 13.7 RETAINING BRACKET SECURING Diagram 13.10 Diagram 13.8 Diagram 13.11...

  • Page 46: Service Completion

    13 Servicing 13.5 Condense Trap and Siphonic Drain FAN CLAMPING BRACKET The condense trap and siphonic drain does not normally need servicing unless material deposits exceed beyond the service SECURING fill level, see diagram 13.13. NUTS (6) To clean the condense trap remove the sump and rinse with water.

  • Page 47: Fault Finding

    14 Fault Finding 14.1 Preliminary fault finding 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.
  • Page 48 14 Fault Finding MODE Diagram 14.4...
  • Page 49 14 Fault Finding CENTRAL HEATING Diagram 14.5...
  • Page 50 14 Fault Finding FAULT CODES Diagram 14.6...

  • Page 51: Central Heating Mode

    14 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 Central heating mode Description...
  • Page 52 14 Fault Finding 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.

  • Page 53: Replacement Of Parts

    15 Replacement of Parts 15.1 General Replacement parts that have associated components that need replacing on removal, i.e. ‘O’ ring, seals, gasket, etc., will be supplied and should be fitted. Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety Executive.

  • Page 54: Gas Valve

    15 Replacement of Parts 15.10 Spark Electrode 15.4 Gas Valve For access, refer to section 15.1. Remove the three securing screws, holding the gas valve to the fan, see diagram 13.7. Remove the spark plug lead and earth lead. Remove the gas valve. Remove the two securing nuts, see diagram 13.6.

  • Page 55: Condensate Trap

    15 Replacement of Parts 15.12 Silencer Assembly (front) Remove the retaining clip from the return pipe. Remove the thermistor from the retaining clip. For access, refer to section 15.1. Note that the polarity of the wiring to thermistor is unimportant. Pull forwards to remove.

  • Page 56: Automatic Air Vent

    15 Replacement of Parts 15.20 Pump (head only) For access, refer to section 15.1. Refer to section 15.1 and drain the boiler heating circuit. Refer to diagram 15.7. Remove the four cap head screws. Carefully remove the pump head together with cable. Do not strain cable.

  • Page 57: Flow Sensor

    15 Replacement of Parts 15.23 Flow Sensor For access, refer to section 15.1. Refer to section 15.1 and drain the boiler hot water circuit. Refer to diagram 15.10. Undo the brass securing nut on the domestic cold water return pipe. Remove the securing clip between the hydroblock and the flow sensor.
  • Page 58 15 Replacement of Parts 15.25 Heat Exchanger FLOW PIPE For access, refer to section 15.1. Refer to section 15.1 and drain the boiler heating circuit and the boiler hot water circuit. Remove the silencer front Pull forwards to remove. The silencer is a push fit so no tools or fixings are required for its removal or fitting, see diagram 13.8.
  • Page 59 15 Replacement of Parts RETAINING CLIP Diagram 15.15 Diagram 15.14 Remove the burner 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 15.15. Taking great care not to damage the surface of the burner. NOTE: Replace the burner gasket and follow the tightening sequence when re-fitting the burner, see diagram 15.15.
  • Page 60 15 Replacement of Parts 15.26 Access to User interface and Main 15.29 Installer Interface Electrical Cartridge Remove the Installer Interface securing screw accessed from beneath the boiler. For access, refer to section 15.1. Carefully pull down the electrical cartridge, disconnect the Hinge down the control box and unclip the rear cover to gain cables.

  • Page 61: Spare Parts

    16.1 Spare Parts When ordering spare parts, contact Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet. Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gas also quote the G.C.

  • Page 62: Manual Handling

    17 Manual Handling Positioning of Appliance for Final Installation – no obstructions. IMPORTANT. With regards to the Manual Handling Operations, 1992 Recommend 2 persons lift appliance to position into place. Fit bracket Regulations, the following lift operation exceeds the recommended securely onto wall before lifting appliance into position.

  • Page 63: Declaration Of Conformity

    18 Declaration of Conformity...
  • Page 64 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT www.high-efficiency.info...

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Flexicom 35cx30cx

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