Glow-worm Flexicom 18sx Installation & Service Manual
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Glow-worm Flexicom 18sx Installation & Service Manual

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2000225264-04 02.06

INSTALLATION AND SERVICING

Flexicom
18sx
G.C. No. 41-315-72
High Efficiency
Condensing System
Boilers
Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT
www.glow-worm.co.uk
1
Supplied By www.heating spares.co Tel. 0161 620 6677

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  • Page 1: Installation And Servicing

    2000225264-04 02.06 INSTALLATION AND SERVICING Flexicom 18sx G.C. No. 41-315-72 High Efficiency Condensing System Boilers Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT www.glow-worm.co.uk Supplied By www.heating spares.co Tel. 0161 620 6677...

  • 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

    In GB this is BS 7871. worm. In IE this is the current edition of I.S.813 “Domestic Gas Any alteration not approved by Glow-worm, could invalidate Installations”. the certification, boiler warranty and may also infringe the The boiler must be connected to a permanent 230V ac, 50Hz current issue of the statutory requirements.

  • Page 5: General Information

    General Information General Note Clearances This boiler is designed for use as part of a sealed water If fixtures are positioned close to the boiler, space must be central heating system with fully pumped circulation. The left as shown in diagram 2.1. pump, expansion vessel and associated safety devices are all fitted within the boiler.

  • Page 6: Appliance Safety Devices

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

  • Page 7: Technical Information

    1 Technical Information FLUE Condensate Connection 19 (Gas & Domestic Water) 22.5 (Central Heating) 167.5 Diagram 1.1 1.1 IMPORTANT NOTICE 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 made to the relevant British Standard Code of Practice.

  • Page 8: Gas Supply

    Upward Piping 1.4 Technical Data Kit is available to facilitate, part No. A2041500. Contact Glow-worm for further details. All dimensions are given in millimetres (except as noted). See diagrams 1.1 and 1.2.

  • 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 A removable compartment door can be placed...

  • Page 10: Flue Options And Terminal Clearances

    flue Ø60/100 - Part No. 2000460485 Flue support clips (3), concentric flue Ø60/100- Part No. A2043900 Additional accessories are available. See Glow-worm “Flue Options 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 Terminal Position

    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: Heating System

    4 Heating System 4.1 General The boiler is for use only with sealed central heating systems. The safety valve is an integral part of the boiler and it cannot be adjusted. The digital read-out on the controls fascia indicates the system pressure when there is no demand.
  • Page 13 4 Heating System SUPPLY PIPE BOILER CONTROL VALVE DOUBLE CHECK VALVE FLOW RETURN HOSE UNION HEATING TEMPORARY CONTROL HOSE CONNECTION CIRCUIT VALVE UNION DRAIN POINT Method 1 DRAIN POINTS BOILER Diagram 4.4 In IE the requirements given in the current edition of I.S.813 TYPE CA BACKFLOW “Domestic Gas Installations”...

  • Page 14: Domestic Hot Water System

    5 Domestic Hot Water System 5.1 General General - All domestic hot water circuits, connections, fittings must be in accordance with the relevant standards and water supply regulations. For GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. For IE: The current edition of I.S.813 “Domestic Gas Installa- tions”.

  • Page 15: Installation Preparation

    6 Installation Preparation 6.1 Appliance Pack IMPORTANT: With regards to the Health and Safety Manual Handling requirements, two persons shall be required to lift the appliance, refer to section 16 Manual Handling. Please check the contents of packs as shown in diagram 6.1. NOTE: The packs are located in the top polystyrene packing.
  • Page 16 6 Installation Preparation Diagram 6.1 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 17: Hanging Bracket

    6 Installation Preparation 6.5 Wall Hanging Bracket Assembly The Wall Hanging Bracket is supplied in the main boiler packaging at the rear of the boiler. Reposition the wall template over the flue hole and mark the position of the fixing holes for the hanging bracket, see diagram 6.2.

  • Page 18: Gas/Water & Appliance Connection

    7 Gas / Water & Appliance Connection 7.1 System Connection JIG SUPPORT The Gas and Water systems can be connected and filled prior PLATE to installation of boiler. All water and gas connections are on the fixing jig with the JIG PLATE exception of the condense drain and safety discharge, the positions of these are shown on the wall template.
  • Page 19 7 Gas / Water & Appliance Connection 7.2 Appliance Connection 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 16 Manual Handling. Rear Flue only This must be fitted before hanging the boiler, refer to Section 9.

  • Page 20: Safety Discharge Valve And Condensate Connection

    8 Safety Discharge Valve & Condensate Connections 8.1 Safety Discharge Valve SECURING The pipe from the safety discharge valve must not discharge CLIP above an entrance, window or any type of public access area. Take the short safety discharge tube, union nut and seal, supplied loose in the boiler fittings pack and fit as shown in diagram 7.3.
  • Page 21 8 Safety Discharge Valve & 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...

  • Page 22: 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 23: Flue Length

    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 24 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 25 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 44mm/metre (2.5°), however, for every 90 or 45...
  • Page 26 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 27 9 Flue Preparation and Installation 9.15 Rear flue - Telescopic Part No. 24 to 28 A2043500. Refer to diagram 9.14 for kit 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 28 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 29: 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 30 9 Flue Preparation and Installation Diagram 9.21 Diagram 9.22 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 31: 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 32 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 33 9 Flue Preparation and Installation Diagram 9.25 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 34 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 35: Electrical Connection

    Any fault arising from incorrect wiring cannot be ALL electrical connections to the boiler put right under the terms of the Glow-worm guarantee. must be permanently fixed to a wall or a All system components must be of an approved type.
  • Page 36 10 Electrical Connection REMOVAL AND REPLACEMENT OF INSTALLER INTERFACE AND CAP VIEW ON UNDERSIDE OF BOILER SECURING SCREW 230Vac FROST STAT 230Vac SYSTEM CONTROLS JUNCTION 3 AMP FUSE DOUBLE POLE CABLE ISOLATOR SECURING SECURING Diagram 10.1 SCREW CLIP 230Vac 50Hz PERMANENT SUPPLY INSTALLER...

  • Page 37: Commissioning

    11 Commissioning 11.1 System Commissioning 5. After filling is complete set the Central Heating temperature to the desired level using the MODE and + (plus) Pre-filling the system SELECTOR buttons as described above. Once the system pipework has been completed it is possible to pre fill the system before mounting the boiler if so desired.
  • Page 38 11 Commissioning 11.4 Testing Should any doubt exist about the gas rate, check it using the gas meter test dial and stop watch at least 10 minutes after the burner has lit, making sure that all other gas burning appliances and pilot lights are off. It should be noted that this appliance will modulate the heat input according to demand.

  • Page 39: Servicing

    12 Servicing Important Notes DRAIN POINTS 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.

  • Page 40: Flue Hood

    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 41 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 42: Heat Exchanger

    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 43: 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 44 13 Fault Finding HEATING FLOW THERMISTOR CONTROL VALVE HEATING WATER RETURN PRESSURE THERMISTOR IGNITER SENSOR UNIT IGNITION ELECTRODE PUMP N L R F EXTERNAL CONTROLS 230V~50Hz MAINS SUPPLY MAIN CONTROL BOARD APPLIANCE INTERFACE BOARD Diagram 13.1 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 45: Central Heating

    13 Fault Finding CENTRAL HEATING 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 46 13 Fault Finding Diagram 13.3 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 47: Central Heating Mode

    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 Central heating mode Possible Causes...
  • Page 48 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 49: Replacement Of Parts

    14 Replacement of Parts 14.1 General DRAIN POINTS 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 the service cock on the boiler, see diagram 14.1.

  • Page 50: Gas Valve

    14 Replacement of Parts 14.6 Gas Valve For access, refer to section 14.1. Remove the electrical plug from the gas valve. Undo the tubing nut holding the gas pipe to the gas valve. Remove the three securing screws, holding the gas valve to LOCKING the fan and remove the gas valve, see diagram 12.6.

  • Page 51: Spark Electrode

    14 Replacement of Parts 14.10 Fan/Gas valve assembly For access, refer to section 14.1. Undo the tubing nut to remove the gas valve from the gas pipe and any electrical connections, see diagram 12.6. Remove the securing nut holding the fan retaining bracket, press down on burner to ease removal of securing nut.
  • Page 52 14 Replacement of Parts FAN/GAS VALVE ASSEMBLY SILENCER REAR Diagram 14.3 HEATING FLOW FLOW PIPE 14.14 Condensate Trap THERMISTOR For access, refer to section 14.1. Diagram 14.4 Remove the drain outlet pipe from the base of the trap. Re- move the condensate drain securing screw and carefully pull the trap forward, see diagram 12.13.
  • Page 53 14 Replacement of Parts 14.17 Pump (head only) CABLE COVER For access, refer to section 14.1. Refer to section 14.2 and drain the boiler heating circuit. Refer to diagram 14.6. Remove the four cap head screws. Carefully remove the pump head together with cable. Do not strain cable.

  • Page 54: Automatic Air Vent

    14 Replacement of Parts 14.19 Automatic Air Vent For access, refer to section 14.1. Refer to section 14.2 and drain the boiler heating circuit. Refer to diagram 14.8. AUTOMATIC Remove the retaining clip to release the automatic air vent. AIR VENT Fit the new automatic air vent and ‘O’...

  • Page 55: Installer Interface

    14 Replacement of Parts USER INTERFACE RETAINING CLIPS CONNECTION CABLE FUSE USER INTERFACE Diagram 14.11 MAIN PCB RETAINING CLIPS CONTROL BOX SECURING Diagram 14.10 REAR COVER SCREW 14.21 Access to User interface and Main HINGE For access, refer to section 14.1. Hinge down the control box and unclip the rear cover to gain access.

  • Page 56: 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 0020014160 DHW thermistor XXXXXX 0020020735 Gas valve XXXXXX 0020020731 Spark electrode XXXXXX 0020020728 Burner XXXXXX 0020023826 User interface XXXXXX 0020014180...

  • Page 57: 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 58 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 59 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 60 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. Supplied By www.heating spares.co Tel. 0161 620 6677...

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