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

Flexicom high efficiency condensing boilers
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Flexicom

Installation and Servicing

12hx
G.C. No. 4-35-28
15hx
G.C. No. 4-35-29
18hx
G.C. No. 4-35-42
24hx
G.C. No. 4-35-6
30hx
G.C. No. 4-35-67
35hx
G.C. No. 4-35-68
High Efficiency
Condensing
Boilers
www.glow-worm.co.uk


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  • Page 1: Installation And Servicing

    Flexicom Installation and Servicing 12hx G.C. No. 4-35-28 15hx G.C. No. 4-35-29 18hx G.C. No. 4-35-42 24hx G.C. No. 4-35-6 30hx G.C. No. 4-35-67 35hx G.C. No. 4-35-68 High Efficiency Condensing 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- - Use safety clothing where appropriate, e.g. gloves, safety worm. footwear. Any alteration not approved by Glow-worm, could invalidate Ensure safe lifting techniques are used the certification, boiler warranty and may also infringe the - Keep back straight.

  • 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 BS689.

  • Page 6: Boiler Design

    Spare Parts “Benchmark” scheme Servicing and Maintenance Glow-worm support the Benchmark initiative. It is very important To ensure the continued efficient and safe operation of the that the Installation, Commissioning and Service Record is boiler it is recommended that it is checked and serviced as completed by the installation engineer and handed over to the necessary at regular intervals.

  • Page 7: Boiler Specification

    1 Boiler Specification BOILER SPECIFICATION 12hx 30hx 35hx Lift weight 25kg (55Ib) 26.5kg (58.4Ib) 12hx 30hx 35hx Total weight (installed) 28kg (62Ib) 29.5kg (65Ib) Gas connection Ø O.D. 5mm. copper Heating Flow and Return connection Ø O.D. 22mm. copper Condensate connection Ø I.D.

  • Page 8: Boiler Dimensions And Hydraulic Schematic

    2 Boiler Dimensions and Hydraulic Schematic Diagram 2.2 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.. 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/7/998. If in doubt seek advice from the 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 Top horizontal telescopic flue (Ø60/00) Top horizontal standard flue (Ø60/00) Part No. A2043600 - Section 0, page 20 Part No. A2043400 - Section 0, page 24 Plume Management Kit basic set, white, concentric flue (Ø60/00) - Part No.

  • 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 0. 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: Water Treatment

    5 Water Systems - General 5.7 Water Treatment 5.1 General Existing system- It is ESSENTIAL that prior to installing the This boiler is designed to provide central heating from a fully new boiler the system is thoroughly flushed. pumped open vented or sealed water system and domestic hot water using a fully indirect cylinder.

  • Page 13: Domestic Hot Water Cylinder

    5 Water Systems - Open Vented 5.8 Vented (Open) Water 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 5mm minimum size.

  • Page 14: Pressure Gauge

    5 Water Systems - Sealed 5.15 Pressure Gauge 5.12 Sealed Water Systems The installation must comply with the appropriate A pressure gauge with a set pointer and covering at least 0 to requirements of the current issue of BS484, BS5449, 4 bar (0 to 60 lb/in2) shall be fitted permanently to the system BS6759, BS6798 and BS7074 Part  and 2.

  • Page 15: Filling A Sealed Water System

    5 Water Systems - Sealed 5.17 Water Makeup SUPPLY Provision should be made for replacing water loss from the PIPE system using a make up bottle mounted in a position higher than the top point of the system, connected through a non-re- turn valve to the return side of either the heating circuit or the BOILER hot water cylinder.

  • Page 16: Installation Preparation

    6 Installation Preparation 6.1 Appliance Pack Please check the contents of packs as shown in diagram 6.. 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: Boiler Fixing

    7 Boiler Fixing 7.1 Wall Hanging Bracket 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.. NOTE: Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable.

  • Page 18: Gas/Water And Appliance Connection

    8 Gas / Water and Appliance Connection 8.1 Gas Connection 8.2 Water Connections Before connection check the supply of local gas. Provision is made for the water connections to be made from The gas supply connection is below the boiler, see diagram above the boiler, see diagram 8..
  • Page 19 9 Condensate Connections Diagram 9.2...

  • Page 20: Flue Length Preparation And Installation

    10 Telescopic Flue - Length, Preparation and Installation 10.1 Flue Length When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2.5º 44mm/metre to allow condensate to run back into the boiler The maximum permissable horizontal flue length is 8 metres and out via the condensate drain.
  • Page 21 10 Telescopic Flue - Length, Preparation and Installation Diagram 0.2 Diagram 0.3...
  • Page 22 10 Telescopic Flue - Length, Preparation and Installation 10.2 Horizontal Telescopic Flue - A2043600 Refer to diagram 0.2 for kit contents. 10.3 REAR Flue If a wall thickness is between 23mm min. to 44mm max. then the flue can be used without extensions. Remove the top flue outlet cover secured with four screws, see diagram 0.4.
  • Page 23 10 Telescopic Flue - Length, Preparation and Installation 10.5 Flue Fitting With the air duct seams aligned and the flue set to the required length ‘Y’, mark the securing hole position in the air duct. Drill a 3mm diameter hole at this position, take care not to pierce the inner flue duct.
  • Page 24 10 Standard Flue - Length, Preparation and Installation 10.6 Flue Length When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2.5º The maximum permissable horizontal flue length is 8 metres 44mm/metre to allow condensate to run back into the boiler plus the flue terminal assembly, this can be achieved by use and out via the condensate drain.
  • Page 25 10 Standard Flue - Length, Preparation and Installation Diagram 0.2 Diagram 0.3...
  • Page 26 10 Standard Flue - Length, Preparation and Installation 10.7 Standard Horizontal Flue - A2043400 Refer to diagram 0.2 for kit contents. 10.8 REAR Flue Remove the top flue outlet cover secured with four screws, see diagram 0.4. Using these screws inserted into the same holes on the boiler, temporarily secure the flue elbow, measure the distance...
  • Page 27 10 Standard Flue - Length, Preparation and Installation 10.10 Flue Fitting Remove the flue elbow. Separate the flue duct from the terminal by twisting to release the terminal catch, then pull out of the retaining seal, refer to diagram 0.7. The flue duct cutting length (L + 11mm.) is shown in diagram 0.7.
  • Page 28 10 Direct Rear Flue - Length, Preparation and Installation 10.11 Direct Rear flue - Telescopic Part No. A2043500. Refer to diagram 0.9 for kit contents. 10.12 Flue Length Measure the distance from the outside wall to the inside wall face. This measurement must not exceed 52mm (465mm if the upward piping kit is used).
  • Page 29 10 Vertical Flue - Length, Preparation and Installation 10.14 Vertical flue Alternatively use 45º bends to avoid horizontal runs, see (b) in diagram 0.22. The vertical flue system is available as an option where the The terminal siting should be as shown in diagram 4.2. boiler position does not permit the use of the top horizontal Measure the distance of flue length required for the flue system.

  • Page 30: Flue Installation

    10 Vertical - Flue Length, Preparation and Installation Flue Installation Remove the top flue outlet cover secured with four screws, see diagram 0.4. Refer to diagram 10.24 and secure the flue adapter in position on top of the boiler with four screws supplied, making sure the nib fits into the locating slot in the boiler casing to ensure correct orientation.
  • Page 31 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 32 10 Twin Flue - Length, Preparation and Installation Diagram 0.28...

  • Page 33: Terminal Position

    10 Twin Flue - Length, Preparation and Installation 10.15 Twin flue 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 34: Installation Details

    10 Twin Flue - Length, Preparation and Installation Installation Details The parts available for a twin flue system installation are shown in diagram 0.29. Boiler Connection Remove the top flue outlet cover secured with four screws, see diagram 0.4. Place the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side, see diagram 0.30.
  • Page 35 2 x 45 bends the maximum length of the Plume Management Kit must be reduced by m. 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 36: Electrical Connection

    This appliance must be wired in accordance with these CARTRIDGE 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 37: Commissioning

    11 Electrical Connection 11.3 Electrical Cartridge Securing FIXING Close the cartridge and secure with the previously removed SCREWS screw. Push the electrical cartridge into the interface housing on completion of the wiring, see diagram .3. Secure with the two cartridge retaining screws provided in the cartridge body.

  • Page 38: Initial Lighting

    APPROXIMATE GAS RATES temperature. MODEL NATURAL GAS G20 After 0 seconds of inactivity the display will reset to indicate m3/h ft3/h the water temperature. 12hx 1.28 3. Turn ON your external controls and select the room 15hx 1.60 56.5 temperature required. 18hx 1.93...

  • Page 39: Instruct The User

    12 Commissioning 12.5 Range Rating 12.7 Completion These boilers are fully modulating, therefore it is not Adjust the boiler temperature control and any system controls necessary to range rate them, however, if desired, you can to their required settings. adjust the boiler in kW increments between 0 and maximun GB: It is a requirement that the “Benchmark”...

  • Page 40: Servicing

    4. 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. 5. 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 4.

  • Page 41: Spark Electrode

    13 Servicing 13.4 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 3.3.
  • Page 42 13 Servicing ELECTRICAL SECURING CONNECTIONS SCREW (3) SECURING SUPPORT BRACKET IGNITION LEAD SPADE CONNECTOR EARTH IGNITER Diagram 3.7 UNIT CONNECTION VALVE TUBING ELECTRICAL PIPE CONNECTION (removed) Diagram 3.5 RETAINING BRACKET SECURING Diagram 3.8 Diagram 3.6 Diagram 3.9...
  • Page 43 13 Servicing 13.8 Casing panel seal check 13.6. Heat Exchanger NOTE: If the functional checks did not indicate poor NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this combustion then it is not necessary to service this component.

  • Page 44: Combustion Check

    13 Servicing 13.9 Combustion Check With the appliance operational connect the CO combustion analyser to the flue elbow test point or if direct rear flue fitted, the test point shown in diagram 3.2. IMPORTANT: Remember to replace the cap on completion of the test.

  • Page 45: Fault Finding

    14 Fault Finding 14.5 Status Codes 14.1 Preliminary fault finding The status codes provide information about the current The following checks should be performed before proceeding operating condition of the boiler and can be accessed through onto specific diagnostics: the diagnostic display, refer to diagram 4.7. •...
  • Page 46 14 Fault Finding BROWN BLUE GREEN/YELLOW GREY GREEN BLACK HEATING FLOW CONTROL YELLOW THERMISTOR VALVE WHITE ORANGE r w y PURPLE PINK HEATING RETURN THERMISTOR IGNITER UNIT bk bk b IGNITION ELECTRODE MAIN CONTROL BOARD APPLIANCE INTERFACE BOARD FLEXICOM HX Diagram 4.4...
  • Page 47 14 Fault Finding Diagram 4.5...
  • Page 48 14 Fault Finding In all circumstances press the reset button to clear the fault. If the fault persists, consult the table below. FAULT CODES Diagram 4.6...
  • Page 49 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 Diagram 4.7...
  • Page 50 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 51: Replacement Of Parts 5

    15 Replacement of Parts 15.1 General 15.7 Fan/Gas valve assembly For access, refer to section 5.. Replacement of parts must be carried out by a competent Undo the tubing nut to remove the gas valve from the gas pipe person. and any electrical connections, see diagram 3.5.

  • Page 52: Condensate Trap

    15 Replacement of Parts 15.10 Burner For access, refer to section 5.. 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 3.0.

  • Page 53: Heat Exchanger

    15 Replacement of Parts 15.13 Heating Return Thermistor RETURN PIPE For access, refer to section 5.. Refer to diagram 5.3. 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.
  • Page 54 15 Replacement of Parts Remove the heat exchanger Remove the burner Undo the screws securing the flanged elbow on the top right Remove the six flanged nuts and two studs that secure the hand side of the heat exchanger and remove the retaining clip burner, note that the two studs also hold the fan clamping from the flanged elbow, see diagram 15 5.
  • Page 55 15 Replacement of Parts 15.15 Casing Seal 15.18 Fuse - Main PCB - Control Box For access, refer to section 5.6. Refer to Section 3.8. The fuse is located at the top left hand corner of the main 15.16 Access to User interface and Main PCB PCB, see diagram 5.8.

  • Page 56: Spare Parts

    16 Spare Parts Key No. Part No. Description GC No 0020020734 ********* 0020020763 Igniter unit ********* 0020020781 Heating flow & return thermistor (2) ********* 0020020735 Gas valve 2hx - 30hx ********* 0020059600 Gas valve 35hx ********* 002002073 Spark Electrode ********* 0020020728 Burner 2hx - 30hx *********...

  • Page 57: Manual Handling

    17 Manual Handling IMPORTANT. of packaging in a responsible manner. Recommend wear suitable With regards to the Manual Handling Opera- cut resistant gloves with good grip to protect against sharp edges and tions, 992 Regulations, the following lift operation exceeds the ensure good grip when handling appliance outside packaging.

  • Page 58: Declaration Of Conformity

    18 Declaration of Conformity...
  • Page 59 Notes...
  • Page 60 0020057279 Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 JT Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

This manual is also suitable for:

35hxFlexicom 35hx15hx18hx24hx30hx

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