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

High efficiency condensing combination boilers
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INSTALLATION AND SERVICING

24cx
G.C. No. 47-047-33
30cx
G.C. No. 47-047-34
High Efficiency
Condensing Combination
Boilers
Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT
Flexicom
www.glow-worm.co.uk
1
2000225263-02 11.05

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  • Page 1: Installation And Servicing

    2000225263-02 11.05 INSTALLATION AND SERVICING Flexicom 24cx G.C. No. 47-047-33 30cx G.C. No. 47-047-34 High Efficiency Condensing Combination Boilers Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT 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.

  • 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

    External wiring must be correctly earthed, polarised and in ance. It is, therefore, important that no alteration is made to accordance with the relevant standards. the boiler, without permission, in writing, by Glow-worm. In GB this is BS 7671. Any alteration not approved by Glow-worm, could invalidate In IE this is the current edition of I.S.813 “Domestic Gas Instal-...

  • Page 5: General Information

    General Information General Note Condensate Drain The condensate drain, see diagram 8.2, must not be modified This boiler is designed for use as part of a sealed water or blocked. central heating system with fully pumped circulation. The pump, expansion vessel and associated safety devices are all Pluming from flue terminal 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 BOILER Flexible Condensate Connection FLOW RETURN 19 (Gas & Domestic Water) 22.5 (Central Heating) Diagram 1.1 167.5 1.2 Statutory Requirements 1.1 IMPORTANT In GB the installation of the boiler must be carried out by a The boiler is supplied in one carton, which includes the competent person as described in the following regulations: appliance packs, see diagram 6.1.

  • Page 8: Technical Data

    1 Technical Information 1.3 Technical Data All dimensions are given in millimetres (except as noted). See diagrams 1.1 and Boiler Specification table. The data label is positioned on the base of the boiler. BOILER SPECIFICATION 24cx 30cx Lift weight 36kg (79Ib) 36kg (79Ib) Total weight (installed) 41kg (90Ib)

  • Page 9: Gas Supply

    1.6 Upward Piping Kit Should any combination of the domestic hot water, heating flow or return pipes come from above the boiler, an Upward Piping Kit is available to facilitate, part No. A2041500. Contact Glow-worm for further details. Diagram 1.2...

  • Page 10: 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 local gas undertaking or Glow-worm. 2.4 Room Ventilation A removable compartment door can be placed...

  • Page 11: 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 “Flexicom Range 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 12: 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 13: Heating System

    4 Heating System 4.1 General 4.3 Flow Rate The boiler is for use only with sealed central heating systems. If it is necessary to alter the flow rate, the system can be The safety valve is an integral part of the boiler and it cannot fitted with a lockable balancing valve in the main flow or be adjusted.
  • Page 14 4 Heating System automatic bypass - fully closed automatic bypass - factory setting automatic bypass - fully open pump speed 1 pump speed 2 1100 1300 1500 -100 Litres/hr Diagram 4.2 4.6 Water Treatment In the case of an existing system, it is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed.

  • Page 15: Domestic Hot Water System

    5 Domestic Hot Water System 5.2 ‘Hard’ Water Areas General - All domestic hot water circuits, connections, fittings must be in accordance with the relevant standards and water supply regulations. The temperatures within the heat exchanger are limited by For GB: Guidance G17 to G24 and recommendation R17 to the boiler control system to minimise scale formation within R24 of the Water Regulations Guide.
  • Page 16 6 Installation Preparation Central Heating x 2 Domestic Water flow Domestic Water return Safety Discharge Valve Diagram 6.1...

  • 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 Systems Connection Assemble the Gas Service Cock and position onto the plastic plug. The Gas and Water systems can be connected and filled prior NOTE: Make sure the drain points are accessible, refer to installation of boiler.
  • 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 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 8.1.
  • 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 9 Flue Preparation and Installation Diagram 9.4 Diagram 9.7 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, do not use mineral oils or grease, silicon grease or water is recommended.
  • 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 extensions, however, for every 90 elbows used the flue length MUST be reduced by 1 metre.
  • 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. A2043500. Refer to diagram 9.14 for kit 24 to 28 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...

  • 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...
  • 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

    This appliance must be wired in accordance with these FLEXICOM COMBI instructions. Any fault arising from incorrect wiring cannot be 230Vac. ROOM THERMOSTAT put right under the terms of the Glow-worm guarantee. AND 230Vac. FROST STAT: All system components must be of an approved type. EXTERNAL PROGRAMMER...

  • Page 36: Commissioning

    11 Commissioning 11.1 Pre-filling the Heating Circuit 4. Switch on the appliance. Set the Central Heating temperature and the Domestic Hot Water temperature to OFF by pressing the MODE button Refer to diagram 11.1 on the User Interface until it shows the appropriate symbol 1.

  • Page 37: Initial Lighting

    11 Commissioning 11.5 Initial Lighting 11.7 Testing - Heating System The lighting procedure of the boiler is fully automated. Check that all external controls are calling for heat. The boiler Check that all external controls are calling for heat. will fire automatically. Fully open all radiator valves, flow The digital display will show water temperature in central control valve, if fitted, see diagram 4.1.

  • Page 38: Servicing

    12 Servicing Important Notes 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 39: Combustion Check

    12 Servicing 12.3 Burner 12.6 Combustion Check Isolate the gas supply at the gas service cock. A combustion check should not be necessary unless a gas carrying component has been replaced or the combustion set- Disconnect the gas supply at the gas valve. ting is suspect.
  • Page 40 12 Servicing FRONT CASING SEAL PANEL THROTTLE OFFSET OFFSET PRESSURE Diagram 12.4 SEAL A competent person should only carry out any adjust- Diagram 12.5 ment to the gas valve, refer to diagram 12.4. 12.7 Casing panel seal check Monitor the combustion reading and at max rate the read- ing should be 9.3% ±...

  • Page 41: 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 42 13 Fault Finding HEATING FLOW THERMISTOR CONTROL VALVE HEATING WATER RETURN PRESSURE THERMISTOR IGNITER SENSOR UNIT IGNITION ELECTRODE PUMP D.H.W. THREE FLOW THERMISTOR VALVE FLOW SENSOR N L R F EXTERNAL CONTROLS 230V~50Hz MAINS SUPPLY MAIN CONTROL BOARD APPLIANCE INTERFACE BOARD COMBI CX Diagram 13.1...

  • Page 43: 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 44 13 Fault Finding Diagram 13.3...
  • Page 45 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 (Priority 3) Possible Causes...
  • Page 46 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 47: Replacement Of Parts

    14 Replacement of Parts 14.1 General CH FLOW & RETURN DRAIN VALVE ISOLATING VALVES 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 48: Gas Valve

    14 Replacement of Parts 14.7 Gas Valve Remove rear silencer. Remove the three securing screws, holding the gas valve to the fan, see diagram 14.4. Remove the gas valve. After re-fitting check the combustion CO and adjust if neces- sary, see section 12.6. After assembly test for gas soundness and purge in accord- ance with the current issue of BS6891or in IE, the current edition of I.S.813 “Domestic Gas Installations”.
  • Page 49 14 Replacement of Parts LOCKING SCREW SPACER EXPANSION VESSEL RETAINING BRACKET EXPANSION VESSEL COUPLING Diagram 14.7 Diagram 14.8 14.10 Expansion Vessel 14.11 Fan/Gas valve assembly For access, refer to section 14.1. For access, refer to section 14.1. Drain the boiler heating circuit, refer to section 14.2. Undo the tubing nut to remove the gas valve from the gas pipe and any electrical connections, see diagram 14.4.

  • Page 50: Spark Electrode

    14 Replacement of Parts FAN/GAS VALVE ASSEMBLY SPARK SILENCER REAR ELECTRODE SECURING NUTS EARTH TAG Diagram 14.9 HEAT EXCHANGER SPARK GAP 14.12 Silencer assembly (rear) Diagram 14.10 For access, refer to section 14.1. Remove the fan/gas valve assembly, see relevant sections. FAN CLAMPING Pull Silencer rear away from fan/gas valve assembly.
  • Page 51 14 Replacement of Parts SECURING SCREW HEATING FLOW FLOW PIPE THERMISTOR CONDENSATE SERVICE Diagram 14.13 TRAP FILL LEVEL Diagram 14.12 14.15 Condense Trap For access, refer to section 14.1. Remove the drain outlet pipe from the base of the trap. Re- move the condensate drain securing screw and carefully pull HEAT RETURN the trap forward, see diagram 14.12.
  • Page 52 14 Replacement of Parts DHW THERMISTOR SECURING SEALING SCREWS (4) WASHERS (4) PLATE TO PLATE HEAT EXCHANGER Diagram 14.15 Diagram 14.16 14.18 Domestic Hot Water Thermistor For access, refer to section 14.1. 14.19 Plate-to-Plate Heat Exchanger Refer to diagram 14.15. For access, refer to section 14.1.

  • Page 53: Automatic Air Vent

    14 Replacement of Parts SECURING CLIP CAP HEAD SCREW (4) CABLE COVER PUMP HEAD SAFETY Diagram 14.17 DISCHARGE VALVE 14.20 Pump (head only) Diagram 14.18 For access, refer to section 14.1. Refer to section 14.2 and drain the boiler heating circuit. Refer to diagram 14.17.

  • Page 54: Flow Sensor

    14 Replacement of Parts FLOW SENSOR RETAINING CLIPS SECURING SCREW (3) RETAINING RETAINING CLIP THREE WAY CLIP VALVE DOMESTIC COLD WATER VIEW SHOWING RETURN UNDERSIDE OF FIXING JIG Diagram 14.20 14.23 Flow Sensor For access, refer to section 14.1. ISOLATION VALVE RETAINING NUT Refer to section 14.3 and drain the boiler hot water circuit.
  • Page 55 14 Replacement of Parts RETAINING CLIPS SECURING SCREW FUSE HEAT MAIN PCB RETAINING EXCHANGER SECURING CLIPS SCREW Diagram 14.22 Diagram 14.23 14.25 Heat Exchanger 14.26 Access to User interface and Main For access, refer to section 14.1. For access, refer to section 14.1. Remove silencer front, flue hood, gas valve / burner assem- bly, spark electrode lead, burner and condense trap.

  • Page 56: Installer Interface

    14 Replacement of Parts CONTROL BOX SECURING REAR COVER SCREW USER INTERFACE CONNECTION CABLE HINGE SECURING SCREW USER HINGE INTERFACE CONTROL Diagram 14.24 Diagram 14.25 14.27 Control Box For access, refer to section 14.1. Hinge down the control box and unclip the rear cover to gain access.

  • Page 57: 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 Electrode XXXXXX 0020020728 Burner XXXXXX XXXXXXX User interface XXXXXX 0020014402 Plate to plate heat exchanger 24/30cx...

  • Page 58: 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 60 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

This manual is also suitable for:

30cx

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