Related Manuals for Glow-worm Flexicom 18sx
Summary of Contents for Glow-worm Flexicom 18sx
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Page 1: Installation And Servicing
Flexicom Installation and Servicing 18sx G.C. No. 41-315-72 30sx G.C. No. 41-047-76 High Efficiency Condensing System Boiler 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: Statutory Requirements
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 Approximate gas rate at part load. PLEASE REFER TO COMMISSIONING... -
Page 8: Boiler Dimensions & 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 arrangement 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 32 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 37 Top horizontal telescopic flue (Ø60/100) Top horizontal standard 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: Water System
5 Water System - Heating 5.5 Bypass 5.1 General The boiler is fitted with an automatic bypass, see diagram 5.2. This boiler is designed for use as part of a sealed water and section 12 Commissioning. The pump remaining central heating system with fully pumped circulation. The pump, expansion vessel and associated safety devices are all conveying capacity is shown in diagram 5.3 fitted within the boiler. -
Page 13: Water Treatment
5 Water System - Heating 5.8 Water Treatment IMPORTANT: Ensure all cleanser is removed from the whole system before adding an inhibitor. Existing system- It is ESSENTIAL that prior to installing the For long-term corrosion protection, after flushing, an inhibitor new boiler the system is thoroughly flushed. - Page 14 5 Water System - Domestic Hot Water 5.9 Unvented DHW System 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.
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Page 15: Installation Preparation
6 Installation Preparation E - Boiler Securing Screw Diagram 6.1... -
Page 16: Site Requirements
6 Installation Preparation 6.1 Appliance Pack 44mm/metre WALL Please check the contents of packs as shown in diagram 6.1. inclined extended The packs are located in the top polystyrene packing. TEMPLATE flue length Remove the carton sleeve and top pack then lift the boiler and its polystyrene base support out of the lower pack. -
Page 17: Gas/Water Connections 7
7 Gas / Water Connections 7.1 System connection NOTE: The Gas and Water systems can be connected and filled prior to installation of boiler, refer to section 12 Commissioning. Make sure the drain points are accessible, refer diagram 5.5. All water and gas connections are on the fixing jig with the exception of the condense drain and safety discharge, the positions of these are shown on the wall template. -
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...
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Page 21: Flue Length Preparation And Installation
10 Telescopic Flue - Length, Preparation and Installation 10.1 Flue Length Multiple Boiler Chimney Flue Length Diagram 10.1 shows the achievable flue length of the The flue length must be calculated and installed according to horizontal telescopic flue kit - A2043600. the relevant standards EN 13384-1 and 2 (C43 flue systems The maximum permissible horizontal flue length is 8 metres only) with reference to the table below and the manufacturers... - 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 secured with four screws, 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 permissible 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 secured with four screws, 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.
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Page 31: Flue Installation
10 Vertical - Flue Length, Preparation and Installation Flue Installation 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 32 10 Vertical - Flue Length, Preparation and Installation Ridge Tile Terminal A ridge tile terminal is available - part no. A2043800, see diagram 10.24. The installation of a ridge tile will be required. A suitable ridge tile is manufactured by: - Aspect East Anglia Limited The Old Mill East Harling...
- Page 33 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 34 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...
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Page 35: 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 36: Boiler Connection
10 Twin Flue - Length, Preparation and Installation 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. Remove the top flue outlet cover secured with four screws, see diagram 10.4. - Page 37 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.
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Page 38: 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 39: Commissioning
11 Electrical Connection Diagram 11.4 Diagram 11.3 11.6 Electrical Connections - Testing 11.5 Electrical Cartridge Securing Carry out preliminary electrical system checks as below: Fit electrical cartridge into the interface housing on completion 1. Test insulation resistance to earth of mains cables. of the wiring, see diagram 11.4. -
Page 40: Initial Lighting
12 Commissioning 12.3 Gas Supply 12.2 Filling the System and Boiler The gas valve is factory set for natural gas (G20) and should 1. Open the two central heating isolating valves marked ‘A’ need no adjustment. Turn on the gas supply at the isolation so that the slots are in line with the length of the valve valve, see diagram 12.2. - Page 41 12 Commissioning MODE MODE Diagram 12.3 NOTE: After ignition the boiler will ramp slowly to full rate Operational Gas Inlet Pressure rather than going immediately to full rate. This is an adaptive With ALL other gas appliances operating, check the feature to cope with small system requirements.
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Page 42: Instruct The User
12 Commissioning 12.8 Completion m3/hr ft3/hr m3/hr ft3/hr Adjust the boiler temperature control and any system controls 74.2 to their required settings. 70.6 GB: It is a requirement that the “Benchmark” Installation, Commissioning and Service Record is completed and left with 109.5 67.1 the user. -
Page 43: 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 14. -
Page 44: Combustion Ratio
CO/CO2 ratio is acceptable. If the combustion reading is not within the acceptable values Advice can be sought from the Glow-worm Technical Helpline. AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure (and gas rate) have been verified, then, it will necessary to adjust the combustion rate of the appliance. -
Page 45: Spark Electrode
13 Servicing 13.1 Servicing NOTE: If the Combustion CO2, CO/CO2 ratio & Gas rate checks did not require adjustment then it will not be necessary to complete a full service. All routine servicing requirements can be achieved by the removal of the front panel, see diagram 13.2. Position the control box into the service position, see diagram 13.3. -
Page 46: Heat Exchanger
13 Servicing 13.5 Burner It should not be necessary to remove the spark electrode from the burner during servicing. NOTE: If the functional checks did not indicate poor Remove the flanged nuts and studs that secure the burner, combustion then it is not necessary to service this note that two studs at the rear also hold the fan clamping component. -
Page 47: Condensate Trap
13 Servicing 13.7 Condensate Trap NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component. The condensate trap does not normally need removing during servicing unless the service fill level is at full, see diagram 13.12. -
Page 48: 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 49 14 Fault Finding Diagram 14.3...
- Page 50 14 Fault Finding CENTRAL HEATING Diagram 14.4...
- Page 51 14 Fault Finding Fault Codes Diagram 14.5...
- 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 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 14.7...
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Page 54: Replacement Of Parts
15 Replacement of Parts 15.1 General Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety DRAIN POINTS Executive. 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 15.1. -
Page 55: Gas Valve
15 Replacement of Parts 15.6 Gas valve For access, refer to section 15.1. 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 the fan and remove the gas valve, see diagram 13.6. - Page 56 15 Replacement of Parts 15.10 Fan/Gas valve assembly For access, refer to section 15.1. Undo the tubing nut to remove the gas valve from the gas pipe and any electrical connections, see diagram 13.6. Remove the securing nut holding the fan retaining bracket, press down on burner to ease removal of securing nut.
- Page 57 15 Replacement of Parts 15.14 Condensate Trap For access, refer to section 15.1. Remove the drain outlet pipe from the base of the trap. Remove the condensate drain securing screw and carefully pull the trap forward, see diagram 13.12. On the condensate trap there is a key symbol that should be in line with the locked padlock symbol on the condense drain.
- Page 58 15 Replacement of Parts 15.17 Pump (head only) For access, refer to section 15.1. Refer to section 15.2 and drain the boiler heating circuit. Refer to diagram 15.6. Remove the four cap head screws. Carefully remove the pump head together with cable. Do not strain cable.
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Page 59: Automatic Air Vent
15 Replacement of Parts 15.19 Automatic Air Vent FLOW For access, refer to section 15.1. PIPE Refer to section 15.2 and drain the boiler heating circuit. Refer to diagram 15.8. Remove the retaining clip to release the automatic air vent. Fit the new automatic air vent and ‘O’... - Page 60 15 Replacement of Parts Diagram 15.13 Diagram 15.12 15.21 Access to User interface and Main For access, refer to section 15.1. Hinge down the control box and unclip the rear cover to gain access. Remove electrical connections from main PCB noting their positions for replacement.
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Page 61: Spare Parts
16 Spare Parts Key No. Part No. Description GC No 0020020734 H42723 0020020763 Igniter unit H42773 0020020781 Heating flow & return thermistor (2) H42792 0020014160 DHW thermistor H36325 0020020735 Gas valve H42724 0020020731 Spark electrode H42720 0020020728 Burner H42718 0020023826 User interface H42784 0020014171... -
Page 62: Manual Handling
17 Manual Handling Unpacking of appliance from carton. IMPORTANT. With regards to the Manual Handling Operations, 1992 Recommend 2 persons unpack appliance from carton. Always keep Regulations, the following lift operation exceeds the recommended working area clear. Cut the carton straps, lift carton up and slide over weight for a one man lift. -
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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Questions and answers
Water is passing straight through the boiler can i buy a new pressure release valve
No, the safety (pressure release) valve is an integral part of the Glow-worm Flexicom 18sx boiler and cannot be adjusted. There is no information provided about a replacement valve being available.
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