Installation and Servicing Condensing Boilers/ Flexicom sx 18sx G.C.No. 41-315-72 30sx G.C.No.
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.
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.
INTRODUCTION WARNINGS Gas Leak or Fault Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking, blowlamps, hot air guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows, ventilate the area. Metal Parts This boiler contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges.
INTRODUCTION CE Mark Gas Supply This boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels. Type test for purposes of Regulation 5 certified by: Notified body 0087. Product/production certified by: Notified body 0086. The CE mark on this appliance shows compliance with: 1.
INTRODUCTION Boiler Design Boiler Design Condensate Drain These boilers are 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. The daily pump exercise programme combined with the built-in frost protection will help to maintain and protect the boiler. Once the controls are set the boiler operates automatically.
TECHNICAL DATA 1 Boiler Specification 14733 Approximate gas rate at part load. PLEASE REFER TO COMMISSIONING C13, C33, C43 C13, C33, C43 SEDBUK rating % 2005 90.3 90.1 SEDBUK rating % 2009 88.4 88.
INSTALLATION 13899 2 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. 14022 Diagram 2.1 -8- Diagram 2.
INSTALLATION 13127 3 Boiler location, Clearances and Ventilation 3.1 Location This boiler is not suitable for outdoor installation. This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements. This boiler is suitable for installation in bathroom zones 2 and 3. In GB this is the current I.E.E. WIRING REGULATIONS and BUILDING REGULATIONS.
INSTALLATION 4 Evacuation of Combustion Gas 4.1 Regulation Only flue accessories supplied by Glow-worm must be used. Different flue outlet configurations can be carried out. • Consult your supplier for more information about the other possibilities and associated accessories. 44 mm/m The maximum length of the flue outlet is defined according to its type (for example C13). H* and J* See diagram 4.2.
INSTALLATION C J V M J E G F H B S K A J N Q U G J J L A 300mm adjacent to a boundary. B The dimension below eaves, balconies and car ports can be reduced to 25mm, as long as the flue terminal is extended to clear any overhang. External flue joints must be sealed with a suitable silicon sealant. C 1500mm between a vertical flue terminal and a window or dormer window. D 1200mm between terminals facing each other. E Vertical flue clearance, 300mm adjacent to a boundary line.
INSTALLATION 4.2 Flue configuration description 4.2.1 4.2.2 Telescopic direct rear flue Ø 60/100 mm Ø 60/100 mm Horizontal concentric flue Ø 60/100 mm or Ø 80/125 mm (C13 type installation) L Ø 60/100 mm L 1 63 4.2.
INSTALLATION 4.2.4 Multiple boiler chimney flue Ø 60/100 mm (C43 type installation) The flue connecting from the appliance to the flue system must be supplied from the manufacturer of the boiler.
INSTALLATION 5.3 Flow Rate 5 Water Systems - General 5.1 General This boiler is designed to provide central heating from a fully pumped sealed water system and domestic water using a fully indirect vented or unvented cylinder. The pump, expansion vessel and associated safety devices are all fitted within the boiler. 5.2 Draining Points Draining taps must be provided at all low points of the system, which will allow the entire system to be drained. Draining taps shall be to the current issue of BS2879.
INSTALLATION 5.5 5.5.1 Water treatment General The Glow-worm Flexicom range of boilers have an Aluminium alloy heat exchanger. Water treatment products used in the system should be suitable for use with Aluminium. Existing system- It is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed. New system- For optimum performance after installation, the boiler and its associated central heating system should also be flushed. 5.5.
INSTALLATION Water System - Domestic Hot Water 5.6 Domestic Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE AND SHOULD NOT BE USED. The domestic hot water cylinder must be of the double feed indirect coil type. It must be suitable for working at a gauge pressure of 0.35bar above the safety valve setting. 5.7 Vented DHW System General - All domestic hot water circuits, connections, fittings must be in accordance with the relevant standards and water supply regulations.
INSTALLATION 5.12 Filling the Sealed System Provision for filling the system at low level must be made, see diagram 5.4. There must be no permanent connection to the mains water supply, even through a non-return valve. NOTE: It is important that fittings used for connection to potable water comply with the water undertakings requirements. 14024 Diagram 5.
15706 INSTALLATION E E - Boiler Securing Screw Diagram 6.
INSTALLATION 6 Installation Preparation 6.1 Appliance Pack Direct Rear Flue only - The flue can now be pulled back through the hanging bracket and secured as shown in diagram 6.3. 13941 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.
INSTALLATION 7 Gas/Water Connections 7.1 System connection JIG SUPPORT PLATE JIG PLATE 14025 JIG SUPPORT PLATE JIG PLATE JIG SUPPORT PLATE Diagram 7.1 14812 8.1 Boiler Hanging - 20 - JIG PLATE Diagram 7.2 8 Boiler Fixing 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.
INSTALLATION A D 5 1 B 2 A 3 13943 A - Central Heating Isolation Valve B - Gas Service Isolation Valve C - Washers (not shown) D - Condensate Connection E - Safety Discharge Pipe 4 E Numbers 1 - 5 show the sequence to be used when tightening to copper tails. Diagram 8.2 9 Safety Discharge Valve and Condensate Connections 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.
15826 INSTALLATION Diagram 9.
INSTALLATION WARNING: This appliance must be earthed. 13921 10 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. ● Do not interrupt the mains supply with a time switch or programmer.
INSTALLATION 13922 13369 Diagram 10.3 Diagram 10.4 10.4 Electrical Cartridge Securing 10.5 Electrical Connections - Testing Fit electrical cartridge into the interface housing on completion of the wiring, see diagram 10.4. Secure with the two cartridge retaining screws provided in the cartridge body. Carry out preliminary electrical system checks as below: 1. Test insulation resistance to earth of mains cables. 2. Test the earth continuity and short circuit of cables. 3.
INSTALLATION Check system soundness. Close the drain point. To comply with the water regulations the remotely installed filling loop connection must be removed. 5. After filling is complete set the Central Heating temperature to the desired level using the MODE and + (plus) SELECTOR buttons as described above. 11.2 Filling the System and Boiler 11.3 Gas Supply 1.
INSTALLATION 14601 MODE MODE Diagram 11.3 temperature by using the MODE and + (plus) or - (minus) SELECTOR buttons. ● The appliance will then continue to fire in central heating mode until the user controls are satisfied. NOTE: After ignition the boiler will ramp slowly to full rate rather than going immediately to full rate. This is an adaptive feature to cope with small system requirements.
INSTALLATION 11.6 Range Rating 11.8 Completion These boilers are fully modulating, therefore it is not necessary to range rate them, however, if desired, you can adjust the output in 1kW increments between: 18sx : 10 - 18kW 30sx : 10 - 30kW as follows: a) Press and hold the ‘MODE’ and “+” button for 5 seconds. The display will change to flashing ‘0’. b) Use the ‘+’ or ‘-’ button to scroll to 96. c) Press ‘MODE’ and hold 5 seconds to confirm. d) The display now shows a flashing ‘d. 0’.
MAINTENANCE IMPORTANT NOTES: 1. 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. 2. It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive. 3.
MAINTENANCE 1. Maximum Rate Check and Adjustment GAS RATE CHECK NOTE: To verify the maximum gas rate CO2 setting the appliance must be checked at the maximum rate first. Press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed.
MAINTENANCE 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. For routine servicing requirements, remove the front casing panel, see diagram 13.2, and hinge down the control panel. Before commencing with a service or replacement of parts. The boiler should be isolated from the electrical and gas supplies. 15585 12.1 Servicing 12.
MAINTENANCE 12.5 Burner NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component. Disconnect the gas supply at the gas valve and electrical 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. Release the igniter unit support bracket, see diagram 12.8. Remove the fan retaining bracket.
MAINTENANCE 12815 12.7 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 12.12. To flush the condense drain carefully pour water into the heat exchanger and check that water flows freely to drain. 12.
MAINTENANCE 13845 13 Fault Finding 13.1 Preliminary fault finding 13.2 Fault Codes Fault codes take priority over all other display functions in the event of a fault occurring, refer to diagram 13.5. If multiple faults occur the codes will be displayed for approx. 2 seconds, alternatively. Diagram 13.
MAINTENANCE 14518 Diagram 13.
MAINTENANCE 13012 CENTRAL HEATING Diagram 13.
MAINTENANCE 14030 Fault Codes Diagram 13.
MAINTENANCE 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. The screen will flash between ‘L1’ and a number. ‘L1’ indicates you have level 1 access, the number indicates the diagnostic number below.
MAINTENANCE 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. 13135 STATE LISTS Diagram 13.
MAINTENANCE 14 Replacement of Parts 14.1 General 14.2 Draining of Boiler Heating Circuit Drain down the Heating Circuit of the boiler only, by closing the heating flow and return isolating valves on the wall mounting jig. Attach a length of hose to the drain point and open the drain valve, see diagram 14.1. Check for leaks. For access, refer to section 14.1. Pull the flue hood securing clips away from the flue hood sump and push flue hood up slightly towards flue hood top, see diagram 12.4.
MAINTENANCE For access, refer to section 14.1. Drain the boiler heating circuit, refer to section 14.2. Undo the coupling at the base of the vessel, see diagram 14.2. Remove the locking screw and spacer from the retaining bracket at the top of the expansion vessel. Whilst holding and also pushing down slightly on the vessel, remove the expansion vessel retaining bracket by unhooking and sliding forward. The expansion vessel can now be removed by sliding it forward clear of its support guides.
MAINTENANCE 13060 14.14 Condensate Trap For access, refer to section 14.1. 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 12.12. On the condensate trap there is a key symbol that should be in line with the locked padlock symbol on the condense drain. To remove the trap turn in the direction of the unlock symbol and carefully pull down clear of the condense drain, see diagram 12.12.
MAINTENANCE 12812 14.18 Safety Discharge Valve For access, refer to section 14.1. Refer to section 14.2 and drain the boiler heating circuit. Refer to diagram 14.7. Undo the safety discharge valve union and remove from the pipework. Remove the retaining clip and withdraw the safety discharge valve. Fit new ‘O’ ring. Refill, vent and pressurise the boiler and check for leaks. 14.19 Automatic Air Vent For access, refer to section 14.1. Refer to section 14.2 and drain the boiler heating circuit.
MAINTENANCE 13001 13003 Diagram 14.13 13004 Diagram 14.12 14.21 Access to User interface and Main PCB 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. Unclip main PCB and remove, see diagram 14.12. Unclip user interface and remove. For replacement, see diagram 14.13 and ensure that the user interface connection cable is refitted.
MAINTENANCE 15 Spare Parts Key No. Part No. Description GC No 1 0020020734 Fan H42723 2 0020020763 Igniter unit H42773 3 0020020781 Heating flow & return thermistor (2) H42792 4 0020020735 Gas valve H42724 5 0020020731 Spark electrode H42720 6 0020020728 Burner H42718 7 0020023826 User interface H42784 8 0020014171 Pump H42760 9 0020079644 Water pressure sensor H80-150 10 0020023825 Main PCB H42783 14519 Diagram 15.
MAINTENANCE 16 Manual Handling IMPORTANT. With regards to the Manual Handling Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a one man lift. General recommendations when handling Clear the route before attempting the lift. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. Do not twist – reposition feet instead. If 2 persons performing lift, ensure co-ordinated movements during lift.
PRIOR TO CO AND COMBUSTION RATIO CHECK The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas supply pressure/rate checked as required prior to commissioning. As part of the installation process, especially where a flue has been fitted by persons other than the boiler installer, visually check the integrity of the whole flue system to confirm that all components are correctly assembled, fixed and supported. Check that manufacturer’s max.
0020107231_04 - 12/14 Subject to engineering changes 0020107231 GLOW-WORM Nottingham Road, Belper, Derbyshire. DE56 1JT www.glow-worm.co.uk Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
