Glow-worm Flexicom cx User Manual

Installation and Servicing
Condensing Boilers/ Flexicom cx 24cx 30cx G.C.No. 47-047-34 35cx G.C.No. 47-047-35
G.C.No. 47-047-33
Guarantee Registration
Thank you for installing a new Glow-worm appliance in your home.
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.
The second year of the parts guarantee, from the beginning of the 13th month onwards after
installation or manufacture, is conditional upon the boiler having been serviced by a competent
person approved at the time by the Health and Safety Executive in accordance with the
manufacturer’s recommendations. We strongly recommend regular servicing of your gas
appliance, but where the condition is not met, any chargeable spare parts or components issued
within the applicable guarantee period still benet from a 12 month warranty from the date of issue
by the manufacturer.
We recommend you complete and return as soon as possible your guarantee registration card.
If your guarantee registration card is missing you can obtain a copy or record your registration by
telephoning the Glow-worm Customer Service number 01773 828100.
Customer Service:
01773 828100
Technical Helpline:
01773 828300
General and Sales enquiries:
Tel. 01773 824639
Fax: 01773 820569
To register your Glow-worm appliance call:
0800 0732142
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit www.centralheating.co.uk for more information.
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.
CONTENTS DESCRIPTION SECTION PAGE
Warnings 4 Important Information 4
INTRODUCTION
INSTALLATION
Statutory Requirements 5 Boiler Design 6 Safety Devices 6 Servicing, Maintenance and Spare Parts 6
Boiler Specication 1 7
Boiler Dimensions and Hydraulic Schematic 2 8 Boiler Location, Clearances and Ventilation 3 9 Evacuation of Combustion Gas 4 10 Water Systems 5 14 Installation Preparation 6 18 Gas/Water Connections 7 20 Boiler Fixing 8 21 Safety Discharge Valve and Condensate Connections 9 22 Electrical Connection 10 24 Commissioning 11 25
MAINTENANCE
APPENDIX
Servicing 12 29 Fault Finding 13 34 Replacement of Parts 14 40 Spare Parts 15 48 Manual Handling 16 49
Benchmark Logbook 50 Commissioning Flow Chart 53
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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.
Sealed Components
Under no circumstances must the user interfere with or adjust sealed parts.
Important Information
Gas Category
This boiler is for use only on G20 natural gas.
Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, it is the Law that ALL gas appliances are installed by a competent person approved at the time by the Health and Safety Executive in accordance with the current issue of these regulations.
Control of Substances Hazardous to Health
Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
Manual Handling
With regards to the “Manual Handling Operations, 1992 Regulations”, the appliance exceeds the recommended weight for a one man lift, refer to section 16 for more information. The handling of the boiler may involve lifting, pushing and pulling, the use of a sack truck may be required. The following handling techniques and precautions should be considered:
- Grip the boiler at its base
- Be physically capable
- Use safety clothing where appropriate, e.g. gloves, safety footwear. Ensure safe lifting techniques are used
- Keep back straight.
- Avoid twisting at the waist.
- Avoid upper body/top heavy bending.
- Always grip using the palm of the hand.
- Use designated hand holds.
- Keep load as close to body as possible.
- Always use assistance if required.
Electrical Supply
The boiler MUST be earthed. All system components shall be of an approved type and all wiring to current I.E.E. wiring regulations. External wiring must be correctly earthed, polarised and in accordance with the relevant standards. In GB, this is BS 7671. In IE, this is the current edition of ETCI rules. The boiler MUST be connected to a permanent 230V ac, 50Hz supply. Connection of the whole electrical system of the boiler, including any heating controls, to the electrical supply MUST be through one common isolator and must be fused 3 Amp maximum. Isolation should be by a double pole switched fused spur box, with a minimum gap of 3mm for both poles. The fused spur box should be readily accessible and preferably adjacent to the
appliance. It should be identied as to its use.
Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3-pin plug both to the current issue of BS 1363, provided they are not used in a room containing a bath or shower. Wiring to the boiler must be PVC 85°C insulated cable, not less than 0.75mm2 (24/0.20mm).
Testing and Certication
This boiler is tested and certicated for safety and performance.
It is, therefore, important that no alteration is made to the boiler, without permission, in writing, by Glow-worm. Any alteration not approved by Glow-worm, could invalidate the
certication, boiler warranty and may also infringe the current
issue of the statutory requirements.
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INTRODUCTION
CE Mark
This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Efciency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the efciency requirements for new hot water boilers red with
liquid or gaseous fuels.
Type test for purposes of Regulation 5 certied by: Notied
body 0087.
Product/production certied by: Notied body 0086.
The CE mark on this appliance shows compliance with:
1. Directive 2009/142/EC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.
2. Directive 73/23/EEC on the harmonisation of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.
IMPORTANT
Where no British Standards exists, materials and equipment
should be t for their purpose and of suitable quality and
workmanship. The installation of this boiler must be carried out by a competent person approved at the time by the Health and Safety Executive in accordance the rules in force in the countries of destination. Manufacturer’s instructions must not be taken as overriding statutory requirements.
Statutory Requirements
In GB, the installation of the boiler must comply with the
requirements of the current issue of BS6798 and be carried out by a competent person, approved at the time by the Health and Safety Executive, as described in the following regulations: The manufacturer’s instructions supplied. The Gas Safety (Installation and Use) Regulations. The appropriate Buildings Regulations either The Building Regulations, The Building Regulations (Scotland),The Building Regulations (Northern Ireland).
The Water Supply (water ttings) Regulations 1999 and water
byelaws 2000, Scotland. The Health and Safety at Work Act, Control of Substances Hazardous to Health (COSHH). The Current I.E.E. Wiring Regulations.
Where no specic instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a competent person approved at the time by the Health and Safety
Executive and installed in accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation. GB: the following Codes of Practice apply: BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593, BS7671.
IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593. NOTE: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK) and the following current issues of:
1) Central heating system specication (CheSS)
and
2) Controls for domestic central heating system and hot water. BRECSU.
Gas Supply
The gas installation must be in accordance with the relevant standards.
In GB, this is BS6891. In IE, this is the current edition of I.S.813 “Domestic Gas
Installations”. The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler. On completion, test the gas installation for tightness using the
pressure drop method and suitable leak detection uid, purge in
accordance with the above standard.
Domestic Hot Water
All domestic hot water circuits, connections, ttings must be
in accordance with the relevant standards and water supply regulations. GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide.
IE: The current edition of I.S.813 “Domestic Gas Installations”.
Heating System
In GB, it is necessary to comply with the Water Supply (Water
Fittings) Regulations 1999 (for Scotland, the Water Byelaws 2000, Scotland). To comply with the Water regulations your attention is drawn to: The Water Regulations guide published by the Water Regulations Advisory Service (WRAS) gives full details of the requirements. In IE, the requirements given in the current edition of I.S.813 “Domestic Gas Installations” and the current Building Regulations must be followed.
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INTRODUCTION
Boiler Design
Boiler Design
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
tted within the boiler. The hot water PRE HEAT temperature
facility will improve the boilers hot water delivery response. The daily pump and 3 way valve exercise programme combined with the built-in frost protection will help to maintain and protect the boiler.
Range Rating
The boilers are fully modulating for central heating, it is therefore not necessary to range rate the boiler. However, if desired, it is possible to range rate the max. CH output in 1kW increments, refer to section 11.
Safety Devices
Electrical Supply Failure
The boiler will not work without an electrical supply. Normal operation of the boiler should resume when the electrical supply is restored. Reset any external controls, to resume normal operation of the central heating. If the boiler does not resume normal operation press the reset button. If the boiler does not resume normal operation after this call your Installation/Servicing company or Glow-worm service.
Overheating Safety
The boiler software is designed to recognise the potential for an overheat lockout and will shutdown before this happens. To restart the boiler, press the reset button on the controls fascia. If the boiler fails to resume normal operation and all external controls are calling for heat, then call your Installation/Servicing company or Glow-worm service.
Safety Discharge Valve
A safety discharge valve and discharge pipe are tted to the
boiler. This valve must not be interferred with, should there 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.
Condensate Drain
A plastic drain pipe must be tted to allow discharge of
condensate to a drain. Condensate should, if possible, be discharged into the internal household draining system. If this is not practical, discharge can be made externally into the household drainage system or a purpose designed soak away, see section 8 for more details.
Pluming from ue terminal
Like all condensing boilers this appliance will produce a plume
of condensation from the ue terminal in cool weather. This is due to the high efciency and hence low ue gas temperature of
the boiler. This is normal and not an indication of a fault.
Frost protection
The appliance has a built in frost protection device that protects the boiler from freezing. With the gas and electric supplies ON and irrespective of any room thermostat setting, the frost protection device will operate the pump when the temperature of the boiler water falls below 8°C. A timer is used so that the temperature can be checked periodically. After 10 minutes the pump will be stopped if the temperature is higher than 10°C or has already reached 35°C. The burner will activate if the boiler temperature does not reach 10°C after 30 minutes or at any time if the temperature drops to 5°C. The burner will switch off when the temperature reaches 35°C.
Condensate Drain Blockage
As a safety feature the boiler will stop working if the condensate drain becomes blocked. During freezing conditions an ice blockage in the condense drain, external to the house would also activate the safety feature. Use warm cloths on the pipe to release an ice blockage. Once the blockage is removed the boiler should then restart.
Servicing, Maintenance and Spare Parts
Servicing and Maintenance
To ensure the continued efcient and safe operation of the
boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage. If this applaince is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, Section 35. Servicing/maintenance should be carried out by a competent person approved at the time by the Health and Safety Executive in accordance with the rules in force in the countries of destination. To obtain service, please call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this literature. After servicing, complete the relevant Service Interval Record
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section of the Benchmark Checklist located on the inside back pages of these instructions.
Spare Parts
Remember, when replacing a part on this appliance, use only spare parts that you can be assured conform to the
safety and performance specication that we require. Do not
use reconditioned or copy parts that have not been clearly authorised by Glow-worm. If a part is required contact Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet. Please quote the name of the appliance, this infomation will be on the name badge on the front of the appliance. If in doubt seek advice from the local gas company or Glow­worm’s own service organisation using the telephone number on the inside front cover of this booklet.
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BOILER SPECIFICATION 24cx 30cx 35cx
Lift weight 36kg (79Ib) 36kg (79Ib) 36kg (79lb)
Total weight (installed) 41kg (90Ib) 41kg (90Ib) 41kg (90lb)
Gas connection Ø O.D. 15mm. copper 15mm. copper 15mm. copper
Heating and return connection Ø O.D. 22mm. copper 22mm. copper 22mm. copper
Domestic hot water connection Ø O.D. 15mm. copper 15mm. copper 15mm. copper
Condensate connection Ø I.D. 21.5mm. plastic 21.5mm. plastic 21.5mm. plastic
Safety valve discharge connection ØO.D. 15mm. copper 15mm. copper 15mm. copper
Heating circuit safety valve (preset) 3 bar (43.5Ibf/in
2
) 3 bar (43.5Ibf/in2) 3 bar (43.5Ibf/in2)
Heating system minimum pressure 0.7bar (10.1Ibf/in
2
) 0.7bar (10.1Ibf/in2) 0.7bar (10.1Ibf/in2)
Maximum domestic hot water circuit 10bar (145Ibf/in
2
) 10bar (145Ibf/in2) 10bar (145Ibf/in2)
1.0bar (14.5lbf/in
2
) 1.0bar (14.5lbf/in2) 1.0bar (14.5lbf/in2)
0.2bar (2.9Ibf/in
2
) 0.2bar (2.9Ibf/in2) 0.2bar (2.9Ibf/in2)
Specific water rate at 35° rise 9.85L/min. 12.3L/min. 14.4L/min
Min. flow rate around C.H. at 20° rise 776L/hr. 1032L/hr. 1204L/hr
Maximum domestic hot water temperature 63° 63° 63°
Expansion vessel capacity 8 litres (1.76 gallons) 8 litres (1.76 gallons) 8 litres (1.76 gallons)
Expansion vessel charge pressure 0.5bar (7.3Ibf/in
2
) 0.5bar (7.3Ibf/in2) 0.5bar (7.3Ibf/in2)
Electrical supply 230V~50Hz fused 3A 230V~50Hz fused 3A 230V~50Hz fused 3A
Electrical rating 180W fused 3A 180W fused 3A 180W fused 3A
EN437 IP clasification IPX4D IPX4D IPX4D
Internal fuse rating on main PCB 2A 2A 2A
Gas supply (governed meter only) and Cat G20 natural gas G20 natural gas G20 natural gas
Gas Category I
2H
I
2H
I
2H
Inlet gas working pressure 20mbar 20mbar 20mbar
Burner % CO
2
case on 9.3 nominal 9.3 nominal 9.3 nominal
Burner % CO
2
case off 9.3 nominal 9.3 nominal 9.3 nominal
1.93 m
3
/h 2.59 m3/h 3.26 m3/h
68.1 ft
3
/h 91.5 ft3/h 115 ft3/h
0.99 m
3
/h 0.99 m3/h 0.99 m3/h
35.1 ft
3
/h 35.1 ft3/h 35.1 ft3/h
Flue type C
13, C33, C43 C13, C33, C43 C13, C33, C43
NOx Class 5 Class 5 Class 5
Heat output condensing mode 18.8kW 24.9kW 31.0kW
Heat input Nett Q = kW DHW max. 25.5 min. 9.4 DHW max. 30.8 min. 9.4 DHW max. 35.8 min. 9.4
CH max. 18.3 min. 9.4 CH max. 24.5 min. 9.4 CH max. 30.8 min. 9.4
Heat output P = kW DHW max. 25.1 min. 9.3 DHW max. 30.0 min. 9.3 DHW max. 35.0 min. 9.3
CH max. 18.0 min. 9.3 CH max. 24.0 min. 9.3 CH max. 30.0 min. 9.3
SEDBUK rating % 2005 90.3 90.0 90.2
SEDBUK rating % 2009 88.4 88.3
89.1
Approximate max. gas rate after 10 mins. from cold
Approximate min. gas rate after 10 mins. from cold
Minimum working pressure to obtain domestic hot water
Minimum working pressure to obtain maximum domestic flow
PLEASE REFER TO THE COMMISSIONING SECTION
Approximate gas rate at part load.
1 Boiler Specication
TECHNICAL DATA
14732
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INSTALLATION
13893
2 Boiler Dimensions and Hydraulic Schematic
All dimensions are given in millimetres (except as noted). The general arrangment of the boiler is shown in diagram 2.1 and the hydraulic and gas schematic, diagram 2.2. The data label is positioned on the front of the inner casing panel.
13089
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Diagram 2.2Diagram 2.1
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INSTALLATION
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. In IE reference should be made to the current edition of I.S.813 “Domestic Gas Installations” and the current ETCI rules.
3.2 Clearances
The boiler should be positioned so that at least the minimum operational and servicing clearances are provided, see diagram
3.1.
Additional clearances may be benecial around the boiler for
installation and servicing.
For ue installations where external access is not practicable,
consideration should be given for the space required to insert
the ue internally, which may necessitate clearance larger than those specied in diagram 3.1.
13127
3.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be tted 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 ue are suitable for installation onto and through
combustible materials provided that:-
1) Minimum 5mm clearance is maintained around the
circumference of the ue (air intake).
2) The combustible surface and xings are suitable for
supporting the load.
3) The minimum clearances from the boiler case are maintained.
3.5 Room Ventilation
The boiler is room sealed so a permanent air vent is not required.
3.6 Cupboard or Compartment Ventilation
Due to the high efciency and low casing temperature of this
boiler, cupboard or compartment ventilation is not necessary.
• Existing ventilation should be investigated for its purpose before removing.
Diagram 3.1
3.7 Airing Cupboard Installation
If the boiler is to be installed in an airing cupboard it is not required to separate the boiler with a non-combustible partition. However, installation and servicing clearances must be maintained, and the boiler kept clear of any clothing. Details of essential features of cupboard/compartment design including airing cupboard installations are given in BS 6891. In IE the current edition of IS 813.
3.8 Roof Restricting Installation
It is not necessary to ensure sufcient clearance between
the boiler and combustible materials or components. This is because the temperature of the boiler will always be less than
o
C due to its nominal heat output.
85
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INSTALLATION
4 Evacuation of Combustion Gas
4.1 Regulation
Only ue accessories supplied by Glow-worm must be used.
Different ue outlet congurations can be carried out.
• Consult your supplier for more information about the other possibilities and associated accessories.
44 mm/m
Standard ue terminal kits have an in-built fall back to the boiler to drain the condensate. These can be tted level
between the appliance and the termination position. All other
extended ues must have a fall of at least 44mm/m
If the ue terminal is positioned near a light source insects may enter the ue system. Where safe and practical to do so advise the homeowner to check the ue outlet and clear visible insects from the terminal end.
H* and J* See diagram 4.2. These dimensions comply with the building regulations, but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions.
Terminal Guard
A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage. If a terminal guard is required, it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal. The guard should be similar to that shown in diagram 4.1. A suitable guard is manufactured by: ­Tower Flue Components Morley Rd. Tonbridge Kent TN9 1RA. Size: 280mm x 165mm. Part No: CGDK3
15583
The maximum length of the ue outlet is dened according to its
type (for example C13).
Whatever the kind of ue system chosen, observe the minimum distances indicated in the chart below to position
the ue terminals.
To install the ue, refer to the separate ue instruction supplied with your appliance.
• Explain these requirements to the user of the appliance.
If necessary, you must install terminal
a
In GB the minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram overleaf.
In IE the minimum distances for ue terminal positioning must
be those detailed in I.S.813 “Domestic Gas Installations”.
The terminal must be exposed to the external air, allowing free passage of air across it at all times.
protection.
Caution! The connection between the ue elbow and the ue outlet must be sealed.
Diagram 4.1
Being a condensing boiler some pluming may occur from
the ue outlet. This should be taken into consideration when
selecting the position for the terminal.
Carports or similar extensions of a roof only, or a roof and one wall, require special consideration with respect to any openings, doors, vents or windows under the roof. Care is required to protect the roof if made of plastic sheeting. If the carport comprises of a roof and two or more walls, seek advice from the local gas supply company before installing the boiler.
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INSTALLATION
J
J
U
E
F
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 ue terminal and a
window or dormer window.
D 1200mm between terminals facing each other.
E Vertical ue clearance, 300mm adjacent to a
boundary line.
F 600mm distance to a boundary line, unless it will
cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting terminal in relation to boundary lines.
G 300mm minimum clearance from a skylight to a
vertical ue or to another vertical ue.
H Vertical ue clearance, 500mm to non-combustible
building material, and 1500mm clearance to combustible building material.
J 300mm above, below and either side of an opening
door, air vent or opening window.
K 600mm diagonally to an opening door, air vent or
opening window.
L 300mm to an internal or external corner.
M 2000mm below a Velux window, 600mm above or to
either side of the Velux window.
N 400mm from a pitched roof or 500mm in regions with
heavy snowfall.
P 25mm from vertical drain pipes and soil pipes.
A
G
J
J
H
K
J
Q
G
B
S
D,T
M
V
C
N
R
L
L
P
L
S
S
Q 200mm below eaves and 75mm below gutters, pipe
and drains.
R The dimension below eaves, balconies and car ports
can be reduced to 25mm, as long as the ue terminal is extended to clear any overhang. External ue
joints must be sealed with suitable silicon sealant.
S 300mm above adjacent ground, balcony or storm
porch.
T 600mm distance to a surface facing a terminal,
unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting terminals in relation to surfaces facing a terminal.
U 300mm clearance alongside another terminal.
V 300mm above roof level.
ll measurements are the minimum clearances required.
A
Terminals must be positioned so to avoid combustion products entering the building.
Support the ue at approximately one metre intervals and at a change of direction, use suitable brackets and xings.
Installations in car ports are not recommended.
A ue outlet should be protected with a guard if persons could come
into contact with it or if it could be damaged.
The ue cannot be lower than 1 metre from the top of a light well due to
the build up of combustion products.
Dimensions from a ue terminal to a fanned air inlet to be determined
by the ventilation equipment manufacturer.
S
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INSTALLATION
4.2 Flue conguration description
4.2.1 Horizontal concentric ue Ø 60/100 mm
or Ø 80/125 mm (C13 type installation)
Ø 60/100 mm
L
1
63
4.2.2 Telescopic direct rear ue Ø 60/100 mm
Ø 60/100 mm
L
Type Max length
Ø 60/100 512 mm
4.2.3 Vertical concentric ue Ø 60/100 mm or Ø 80/125 mm (C33 type installation)
Key
1 Gasket (tted)
1
Key
1 Gasket (tted)
Ø 60/100 8 m Ø 80/125 20 m
Ø 80/125 mm
L
Type Max length
L
Type Max length (L)
Ø 60/100 8 m Ø 80/125 20 m
Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m.
Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m.
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4.2.4 Multiple boiler chimney ue
L
B
A
1
2
3
4
5
Ø 60/100 mm (C43 type installation)
The ue connecting from the appliance to the ue system must be supplied from the manufacturer of the boiler.
C43 ue systems must not be a 'pressurised system' but act under natural draught principles
C43 type ue systems must have their own condensate drain tted and not allow condensate to mix into other appliances
INSTALLATION
Multiple Boiler Chimney Flue Length
The ue length must be calculated and installed according to the relevant standards EN 13384-1 and 2 (C43 ue systems
only) with reference to the table below and the manufacturers instructions supplied.
The appliance maximum ue length must be included when calculating the overall design of the ue system.
NOTE: The horizontal ue terminal must be removed.
Flexicom
24cx
Exhaust mass rate (g/s)
At Min Thermal Load (40C°/30°C)
At Max Thermal Load (80C°/60°C)
Exhaust temperature (ºC)
At Min Thermal Load (40C°/30°C)
At Max Thermal Load (80C°/60°C)
11.67 14.10 16.39
Key 1 Pressure balancing system 2 Air-inlet pipe 3 Collector pipe 4 Boiler 5 Inspection hatch A Final storey
B Ground oor
Type Max length (L)
Ø 60/100 8 m
Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m.
30cx
Flexicom
Flexicom
35cx
4.30 4.30 4.30
33.2 33.2 36.0
73.3 87.4 86.0
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INSTALLATION
5 Water Systems - General
5.1 General
This boiler is 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 tted
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. Drain points for the appliance are provided at the positions shown in diagram 5.1.
13925
Diagram 5.1
13102
- 14 -
Diagram 5.2
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INSTALLATION
5.3 Water treatment
5.3.1 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 ushed.
New system- For optimum performance after installation, the boiler and its associated central heating system should also be
ushed.
For long-term corrosion protection, after ushing, an inhibitor
should be used, refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems.
Debris left in the system can damage the boiler, reduce efciency and also lead to system corrosion and generation of ammable gas. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty.
The pH value of the system water must be between 6.5 and 8.5 or the appliance guarantee will be invalidated.
5.3.3 Inhibiting the system
Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system is exposed to freezing conditions, to the heating system in accordance with the DWTA code of practice and inhibitor manufacturer’s guidelines.
Examples of suitable inhibitors are:
Sentinel X100
Fernox protector F1
Articially softened water must not be used to ll the central heating system.
Sealing agents - The addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger.
Ensure that the pH of the treated system water is
i
i
conrmed as between 6.5 and 8.5 and free of any residual deposits from the ushing process.
Ensure the Benchmark Logbook is completed with information on water treatment products before handing over to the user.
Before ushing the system
• Ensure that the system and pipe work is in good working order.
• Where possible keep the existing boiler/circulating pump in
place when ushing the system.
5.3.2 Flushing the system
• Fill the system with cold water and check for leaks.
• Open all drain cocks and drain the system.
Close drain cocks and add a suitable ushing agent (cleaner) compatible with Aluminium at the correct strength for the system conditions in accordance with the manufacturer’s instructions.
Examples of suitable ushing agents/cleansers are:
Sentinel X300, X400
Fernox F3
Circulate the ushing agent before the boiler is red up.
• Run the boiler/system at normal operating temperature as
directed by the manufacturer of the ushing agent.
It is essential to drain and thoroughly ush the whole system to remove the ushing agent and debris.
It may be necessary to use a power ushing machine to aid the cleansing procedure in some circumstances.
Close the drain cocks and rell with fresh water and a suitable inhibitor
• Vent any air from the boiler and system.
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INSTALLATION
5 Water systems - Domestic Hot Water
5.4 General
All domestic hot water circuits, connections, ttings 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 Scotland, the Water
Byelaws 2000, Scotland).
For IE: The current edition of I.S.813 “Domestic Gas Installations”.
5.5 Water Pressure
The minimum working pressure to obtain the maximum
domestic ow is:-
24cx 1.0bar 30cx 1.0bar 35cx 1.0bar The maximum working pressure of the domestic hot water circuit is 10 bar. If the cold water supply pressure exceeds this,
then a pressure-reducing valve must be tted in the supply to
the boiler.
5.6 ‘Hard’ Water Areas
The temperatures within the heat exchanger are limited by the boiler control system to minimise scale formation within the hot water pipework. However, in areas where the water is ‘hard’ (i.e. more than 200mg/litre), it is recommended that the hot water
setting is reduced and that a scale reducer is tted, refer to the
manufacturer’s instructions or consult the local water company for additional advice.
5 Water Systems - Sealed Central Heating system
5.8 Flow Rate
If it is necessary to alter the ow rate, the system can be tted with a lockable balancing valve in the main ow or return pipes shown as valve “A” in diagram 5.3. The ow rate through the
boiler must not be allowed to fall below that given in section 1 -
Specication Table.
5.9 Bypass
The boiler is tted with an automatic bypass.
Diagram 5.2 shows the pump head remaining for the heating system depending on the bypass setting and the speed setting of the pump, see section 11 Commisioning.
Ensure that under no circumstances does the ow rate drop below the gure specied, refer to section 1 - Specication
Table and section 11.9.
5.10 Safety Valve
The safety valve is an integral part of the boiler and it cannot be adjusted. The pipe from the safety discharge valve must
not discharge above an entrance, window or any type of public access area.
15725
5.7 Domestic Water Flow Rate
The water ow rate is restricted to a maximum 9.4 l/min for
24cx, 11.7 l/min for 30cx and 13.0l/min for 35cx by a restrictor
factory tted within the boiler.
- 16 -
Diagram 5.3
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INSTALLATION
5.11 Filling the Sealed System
The boiler is supplied with a lling device, see diagram 5.1. This lling device is designed to enable the lling and
pressurisation of the system in the event of loss of pressure. NOTE: The water pressure at the boiler must be at least
1.2bar to enable lling the boiler to a minimum pressure. If not
pressurisation must be carried out by an alternative lling loop. Suitable external lling systems are shown diagramatically,
see diagram 5.4. The system should be pressurised to 1bar, indicated on the digital display with no heating demand.
5.12 Expansion Vessel
The boiler has an integral expansion vessel with a capacity of 8 litres (1.76 gallons), with a charge pressure of 0.5bar. NOTE: The expansion vessel volume depends on the total water system volume and the initial system design pressure. In GB, Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1. In IE, current edition of I.S.813 “Domestic Gas Installations”.
12253
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Diagram 5.4
- 17 -
INSTALLATION
H
H - Boiler Securing Screw
15708
- 18 -
Diagram 6.1
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INSTALLATION
6 Installation Preparation
6.1 Appliance Pack
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.
6.2 Site Requirements
The boiler mounting wall should be suitable for the weight of the
appliance and be true and at.
NOTE: Due to the varied site conditions we do not supply
xings and advise that the installer should supply those which
are suitable.
6.3 Wall Template
Take the wall template from the document pack located within the top polystyrene packing and place in the desired position on the wall, giving due consideration to the required boiler
clearances, see section 3, and the ue you are tting. Mark the position of the ue centre, if tting a side ue, extend the ue centre line into the corner then 149mm along the
adjacent wall, see diagram 6.2.
For extended side ues, the ue hole centre should be
determined by extending the dashed inclined line on the template to the side wall, then 149mm along the adjacent wall, see diagram 6.2. This dashed line is drawn at 44mm/metre (2.5°) rise from the boiler.
To allow for the ue passing through the wall at this angle a
125mm hole should be drilled irrespective of internal or external installation.
Remove the wall template whilst drilling the ue hole.
13894
Diagram 6.2
14810
HANGING BRACKET FIXINGS
6.4 Flue Hole Cutting
External access ue installation can use a 105mm diameter
core drill.
Internal access only ue installation will need a 125mm
diameter core drill.
NOTE: The ue is designed with an internal fall of 44mm/metre
(2.5°), therefore the hole can be drilled horizontally.
If ue extension pipes are to be used then a core drill size of
125mm is required. This will allow the extension pieces to slope at 44mm/metre (2.5°) towards the boiler.
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 ue hole and mark the position of the xing holes for the hanging bracket, see diagram
6.3.
NOTE: Due to the varied site conditions we do not supply
xings and advise that the installer should supply those which
are suitable.
Drill xing holes and insert suitable wall plugs.
Direct Rear Flue only - If external access is not available the
ue to be used should be assembled as described in sections
10.11 to 10.13 and inserted through the hole in the wall before
tting the wall hanging bracket. Fit the xing jig support plate to the bottom of the wall hanging
bracket, push down to locate.
Mark, drill and plug at xing points and secure the jig support
plate, see diagram 6.3.
JIG SUPPORT PLATE FIXINGS
Diagram 6.3
Direct Rear Flue only - The ue can now be pulled back
through the hanging bracket and secured as shown in diagram
6.3.
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INSTALLATION
7 Gas/Water Connections
7.1 System connection
NOTE: The appliance may contain a small amount of water,
place a water container beneath the boiler connections
NOTE: The Gas and Water systems can be connected
and lled prior to installation of boiler, refer to section 12
Commissioning. Make sure the drain points are accessible, refer diagram 5.4.
All water and gas connections are on the xing jig with the
exception of the condense drain and safety discharge, the positions of these are shown on the wall template. An Upward Piping Frame, part no. A2041500 should be used if the supplies come from above the boiler otherwise the pipes will have to be chased into the wall.
Assemble the pipes to the jig as shown in diagram 7.1.
Fit ‘O’ ring seal to the Double Check Valve assembly.
13129
Fit the Central Heating Isolation Valve handles and secure with screws provided.
Fit the assembled Jig Plate to the Support Plate as shown in diagram 7.2.
Assemble the Gas service isolation valve and position onto the plastic plug.
Plumb system pipe work to the copper tails. Do not subject isolation valves to heat.
Fit Double Check Valve into Isolation Valve and secure with the wire retaining clip.
Prior to lling the water system ensure that the blanking plugs
and isolation valves are secured.
Flush out the domestic hot water and the heating systems.
The whole of the gas installation, including the meter, should be inspected, tested for tightness and purged in accordance with the current issue of BS6891 and in IE the current edition of I.S.813 “Domestic Gas Installations”.
12957
- 20 -
Diagram 7.1
Diagram 7.2
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INSTALLATION
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 16 Manual Handling.
IMPORTANT: Direct Rear Flue only - The direct rear ue must be tted before hanging the boiler, refer to sections 10.11 to
10.13, and the rear outlet cover plate should be removed.
The appliance and jig (pre-lled) may contain a small amount of
water, place a water container beneath the boiler connections. Make sure the isolation valves are closed before disconnecting the blanking plugs and discarding the jig plate. Position the sealing washers supplied in the Loose Items pack, as shown in diagram 6.1.
Lifting the boiler into position, lean the top of the boiler slightly to the wall and position just above the hanging bracket. Lower the boiler slowly, push back and engage onto the hanging bracket making sure the boiler is located over the retaining bosses, secure with screw provided, see diagram 8.1. Remove the protective caps.
Engage the xing jig connections, ensuring that the previously
positioned washers have not been disturbed.
There are ats on the body of the valves for locating a spanner
to aid tightening to copper tails using the tightening sequence shown in diagram 8.2.
Make good the nal connections.
14811
SECURING SCREW
Diagram 8.1
A - Central Heating Isolation Valve B - Domestic Hot Water C - Gas Service Isolation Valve D - Domestic Cold Water E - Washers (not shown) F - Condensate Connection G - Double check inlet valve H - Safety Discharge Valve
13926
Numbers 1 - 5 show the sequence to be used when tightening to copper tails.
Diagram 8.2
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INSTALLATION
9 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 t
as shown in diagram 9.1. This must be extended, using not less than 15mm o.d. pipe, to discharge, in a visible position, outside the building, facing downwards, preferably over a drain. To ease future servicing it is advisable to use a compression
type tting to extend the safety discharge valve tube.
The pipe must have a continuous fall and be routed to a position so that any discharge of water, possibly boiling, or steam cannot create any danger to persons, damage to property or external electrical components and wiring.
9.2 Condensate Trap and Siphonic Drain
Connection
A exible condensate outlet pipe is tted and should be used
to couple the condensate trap and siphonic drain to a 22mm
to 25mm O.D. non corrosive plastic pipe (overow pipe), see
diagram 8.2.
IMPORTANT: Please remove the bung from the exible pipe before tting to a drain outlet pipe.
12667
NOTE: the pipe should have a fall of a least 2.5o 44mm/metre away from the boiler. Condensate should, if possible be discharged into the household internal drainage system. If this is not practicable, discharge can be allowed into the external household drains or a purpose designed soak away, refer to diagram 9.2. It is recommended that any external condensate drain pipe is protected and also preferably of 32mm diameter, to prevent freezing in adverse weather conditions. The condensate is discharged periodically in ‘slugs’ by siphonic action. It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a 75mm high trap inside the boiler. Fitting an extra trap may cause the boiler siphon to work incorrectly. Refer to BS5546 or BS6798 for advice on disposal of boiler condensate.
Diagram 9.1
- 22 -
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INSTALLATION
15826
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Diagram 9.2
- 23 -
INSTALLATION
10 Electrical Connection
WARNING: This appliance must be earthed.
● 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.
● Connection of the whole electrical system and any heating
system controls to the electrical supply must be through a common isolator.
● Isolation should preferably be by a double pole switched
fused spur box having a minimum contact separation of 3mm on each pole. The fused spur box should be readily accessible
and preferably adjacent to the boiler. It should be identied as
to its use.
● A fused three pin plug and shuttered socket outlet may be
used instead of a fused spur box provided that it is not used in a
room containing a xed bath or shower.
● The boiler is suitable for installation in bathroom zones 2 and
3.
10.1 Electrical Wiring
Remove the electrical cartridge from the ttings pack.
Remove the securing screw to open the cartridge. NOTE: There are two screws supplied loose in the electrical cartridge, these will be required to secure the cartridge into the electrical interface housing.
13921
Slacken the screws of the cable strain relief in the electrical cartridge, see diagram 10.1.
Route the mains supply and system cables through the strain relief and connect to the relevant plug, refer to the appropriate sections 10.2 or 10.3.
Initially, if system controls are not tted, leave the “Red Link” in
place, this will create a continuous demand.
10.2 System Controls 24V
WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V CONNECTION PLUG.
Connect the mains supply and system heating controls e.g. room thermostat as diagram 10.2.
External controls should be tted in accordance with the rules
in force.
10.3 Mains Voltage System Controls
WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V CONNECTION PLUG.
Diagram 10.1
13368
Connect mains supply and system controls as diagram 10.3.
External controls should be tted in accordance with the rules
in force.
- 24 -
Diagram 10.2
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INSTALLATION
13369
13922
Diagram 10.3
10.4 Electrical Cartridge Securing
With the gas service isolation valve closed and with no demand
from any external controls, t the electrical cartridge into the
interface housing, see diagram 10.4. Secure with the two cartridge retaining screws provided in the cartridge body.
11 Commissioning
IMPORTANT: If the appliance is to be left out of operation after
initial commissioning, ensure all system cleansing and inhibition has been carried out fully and that power is left on to the
appliance. This is to ensure that there is no risk of ammable
gas collecting in the system due to corrosion. At the time of commissioning, complete all relevant sections of the Benchmark Checklist located in the inside back pages of this document.
11.1 Pre-lling the Heating Circuit
Do Not operate the boiler without water. The commissioning should be carried out by a competent person approved at the time by the Health and Safety
Executive and in accordance with the current issue of BS6798.
Make sure that the system has been thoroughly ushed out with
cold water and that all cleanser if used has been removed. With the gas service isolation valve closed, with no demand from any external controls and the power supply to the boiler switched off. Test for gas tightness and purge air from the gas supply.
Diagram 10.4
10.5 Electrical Connections - Testing
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. Test the polarity of the mains.
NOTE: If you require to test the appliance refer to section 13.
Refer to diagram 11.1
1. Ensure that the exible hose is connected to the double
check valve by tightening the knurled nut marked ‘E’.
2. Ensure that the water isolation valves are securely tightened onto the jig blanking plugs.
3. Open the Central Heating Flow and Return isolation valves marked ‘A’ using a screwdriver or a 4mm allen key - slot in line with the axis of the isolation valves (shown closed in diagram).
4. Ensure ALL cold water taps are shut off then open the Domestic Cold Water isolation valve marked ‘B’ using a screwdriver or a 3mm allen key - slot in line with the axis of the isolation valve (shown closed in diagram). NOTE: A manometer kit accessory, part no. 0020016995 is
available to monitor system pressure during lling, this should
be attached to the drain point connection marked ‘C’ and the drain point opened to enable a reading of the system pressure to be taken. If the manometer kit is not used caution should be taken not to overpressurise the system.
5. Open the two lling taps marked ‘D’ by rotating them through 90° to ll the heating system to a pressure of
1.0bar. Close the two lling taps.
6. Vent all air from the system - repeat step 5 as neccessary until the system is full and all the air has been removed.
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- 25 -
INSTALLATION
7. Close the Domestic Cold Water isolation valve marked
‘B’ using a screwdriver or a 3mm allen key (shown closed in diagram).
8. Close the Central Heating Flow and Return isolation
valves marked ‘A’ using a screwdriver or a 4mm allen key (shown closed in diagram). If the manometer kit was used, close drain point marked ‘C’ and remove the manometer.
9. To comply with the water regulations the exible hose
must be disconnected from the double check valve - undo
the knurled nut marked ‘E’ and pull the exible hose from
the double check valve.
11.2 Filling the System and Boiler
1. Ensure that the exible hose is connected to the double
check valve by tightening the knurled nut marked ‘E’.
2. Open the Central Heating Flow and Return isolation valves
marked ‘B’ using a screwdriver or a 4mm allen key - slot in line with the axis of the isolation valve (shown closed in diagram).
3. Open the Domestic Cold Water cock marked ‘B’ using a
screwdriver or a 3mm allen key - slot in line with the axis of the isolation valve (shown closed in diagram).
4. Switch on the appliance, refer to diagram 11.2.
Set the Central Heating temperature and the Domestic Hot Water temperature to OFF by pressing the MODE button on the User Interface until it shows the appropriate symbol
or
and then pressing the - (minus) SELECTOR button. The display will now permanently show system pressure.
5. Open the two lling taps marked ‘D’ by rotating them
through 90O to ll the heating system to a pressure of
1.0bar. Close the two lling taps marked ‘D’.
6. Vent all air from the system - repeat step 5 as neccessary until the system is full and all the air has been removed.
7. After lling is complete set the Central Heating
temperature and the Domestic Hot Water temperature to the desired level using the MODE and + (plus) SELECTOR buttons as described above.
8. To comply with the water regulations the exible hose
must be disconnected from the double check valve - undo
the knurled nut marked ‘E’ and pull the exible hose from
the double check valve.
11.3 Filling Domestic Water Circuit
Fully open any valves in the domestic water supply to the boiler. Open the domestic water isolation valve, slot in line with the length of the valve (shown closed in diagram).
Open all hot water taps in turn and close them when water
ows. Check for water soundness of the complete domestic
water system.
The water ow rate is restricted by a restrictor factory tted to
the boiler.
11.4 Re-pressurising System
1. Ensure that the exible hose is connected to the double
check valve by tightening the knurled nut marked ‘E’.
2. Open the two lling taps marked ‘D’ by rotating them
through 90
1.0bar. Close the two lling taps marked ‘D’.
3. Vent all air from the system - repeat step 2 as neccessary until the system is full and all the air has been removed.
4. To comply with the water regulations the exible hose must
be disconnected from the double check valve - undo the
knurled nut marked ‘E’ and pull the exible hose from the
double check valve.
O
to ll the heating system to a pressure of
11.5 Gas Supply
The gas valve is factory set for natural gas (G20) and should need no adjustment. Turn on the gas supply at the isolation valve, see diagram 11.1. Check the supply pressure at the pressure test point is 20mbar.
Commissioning should only be carried out by a competent person approved at the time by the Health and Safety Executive.
11.6 Initial Lighting
NOTE: Ensure that initial lighting of the appliance takes place with the front casing door removed and the control box lowered. Initially run the appliance pump to ensure all air has been vented from the system (observe the operation of the auto air vent, if possible). The combustion for this appliance has been checked, adjusted and preset at the factory for operation on natural
gas (G20) as dened on the appliance data label. Do not adjust the Gas/Air ratio valve.
As an option, a chargeable boiler performance and function service can be provided by Glow-worm Service by calling telephone No. 01773 828100. It is a requirement to measure and record the CO value and CO/CO2 ratio. Guidance on measuring the values can be documented in the Benchmark log book at the very back of this manual.
- 26 -
13895
Diagram 11.1
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MODE
INSTALLATION
14507
MODE
DO NOT operate the boiler without water. Check that all external controls are calling for heat. Set the Central Heating temperature and the Domestic Hot Water temperature to ON by pressing the MODE button on the User Interface until it shows the appropriate symbol
or The lighting procedure of the boiler is fully automated. The digital display, refer to diagram 12.2, will show water temperature in central heating demand.
● The appliance will enter a self checking routine then the
fan should start and the ignition will commence. The boiler, if necessary, will automatically repeat the ignition sequence a further 4 times.
● If the burner fails to ignite “F1” will be displayed, initially,
this may be due to air in the gas supply line.
● Once the system has been purged of air. Set the hot water
to the desired temperature by using the MODE and + (plus) SELECTOR buttons. Open a hot water tap, the diverter valve motor will move to hot water supply and the display will read domestic hot water temperature. Check that hot water is available at all taps, then close.
● Set the Central heating water temperature to the desired
temperature by using the MODE and + (plus) SELECTOR buttons. The appliance will then continue to operate in central heating
until the user controls are satised or there is another demand
made for hot water.
and then pressing the - (minus) SELECTOR button.
11.7 Check the Gas Inlet Pressure & Gas Rate
The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.On completion, test the gas installation for tightness using the pressure drop method and suitable leak detection
uid, purge as necessary.
NOTE: Due to the modulating operation of the boiler and the need to check the gas inlet pressure and measure the gas rate at maximum rate, it will be necessary to force it to maximum.
Diagram 11.2
After a period of 10 minutes, with the boiler operating in C.H. mode, turn on several hot water taps, this will operate the boiler at maximum rate.
Operational Gas Inlet Pressure
With ALL other gas appliances operating, check the operational supply pressure at the gas service isolation valve test point, see diagram 11.1. The nominal supply pressure for Natural Gas (G20) is 20mbar. Turn the taps and appliances off, then disconnect the pressure gauge. Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar.
NOTE:
The BURNER PRESSURE cannot be measured and is
not used to measure the gas rate.
Gas Rate
Make sure that ALL other gas burning appliances and pilot lights are off. Check the gas rate using the gas meter test dial and stop watch, at least 10 minutes after the burner has lit. The approximate maximum gas rates are: 24cx : 1.9m3/h (68ft/3/h) 30cx : 2.6m3/h (92ft/3/h) 35cx : 3.3m3/h (115ft/3/h)
kW m3/hr ft3/hr kW m3/hr ft3/hr
20 2.1 74.2 30 3.2 113 19 2.0 70.6 29 3.1 109.5 18 1.9 67.1 28 3.0 106 17 1.8 63.6 27 2.9 102.4 16 1.7 60.0 26 2.8 98.9 15 1.6 56.5 25 2.6 91.8 14 1.5 53.0 24 2.5 88.3 13 1.4 49.5 23 2.4 84.8 12 1.3 45.9 22 2.3 81.2 11 1.2 42.4 21 2.2 77.7 10 1.1 38.9
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- 27 -
INSTALLATION
11.8 Central Heating Range Rating
The boilers are fully modulating for central heating, therefore it is not necessary to range rate them, however, if desired, you can adjust the CH output in 1kW increments between: 24cx : 10 - 18kW 30cx : 10 - 24kW 35cx : 10 - 30kW as follows: a) Press and hold the ‘MODE’ and “+” button for 5
seconds. The display will change to ashing ‘0’.
b) Use the ‘+’ or ‘-’ button to scroll to 96.
c) Press ‘MODE’ and hold 5 seconds to conrm. d) The display now shows a ashing ‘d. 0’.
e) The part load setting is displayed in kW. Press ‘MODE’ the max rate will be indicated, to change the value to the desired setting, use the ‘+’ or ‘-’ button.
f) Press ‘MODE’ for 5 sec to conrm the new setting
has been saved. g) Press and hold ‘MODE’ and “+” to exit.
Please refer to the above table to check the gas rates.
11.9 Heating System
Ensure that the external controls and programmer are calling for heat.
Fully open all radiator valves, ow control valve, if tted, see
diagram 5.3. Press the “MODE” button to change to the CH.
Balance the radiators as required and if tted adjust valve to
give the required system differential. Turn off all radiators that can be shut off by the user and check to see if less than the maximum differential allowed of 20
ow and return.
NOTE: Should the system require that the appliance has to be adjusted, the front casing will need to be removed as described in the servicing section 12 and the control box lowered into its service position. The appliance pump has two speeds and can be adjusted to suit the requirements of the system. The appliance has an inbuilt automatic adjustable bypass valve, see diagram 11.3. The pressure can be adjusted between approx 1.5 and 3.5mH
2.5mH
2O. The pressure changes by approx 0.1mH2O for each
full turn of the bypass screw. Turning clockwise increases the pressure and turning anti-clockwise decreases the pressure. Allow the system to reach maximum temperature then switch off the boiler by isolating from the electrical supply. Drain the entire system rapidly whilst hot, using the drain taps at all the low points of the system. Fill and vent the system as described previously in section 11.2.
Lock or remove the handle from control valve, if tted.
Adjust the boiler temperature controls and any system controls to their required settings.
2O but is factory pre-set to approx
o
C can be achieved across
11.10 Completion
Ensure that the magnetic lighting instruction label is placed on the surface of the boiler casing. GB: In addition it is necessary to complete the “Benchmark” logbook. IE: it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S.813. An example of this is given in the current edition of I.S.813.
13072
Diagram 11.3
11.11 Instruct the User
● Demonstrate, then instruct the User about the lighting
procedure and heating system controls operation.
● Advise that to ensure the continued efcient 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 installation conditions and usage, but in general, once a year should be enough.
● Draw attention, if applicable, to the current issue of the Gas
Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK.
● The user shall not interfere with or adjust sealed components.
● It is the Law that any servicing is carried out by a competent
person approved at the time by the Health and Safety Executive.
● Advise the user that, like all condensing boilers this appliance will produce a plume of condensation from the ue terminal in cool weather. This is due to the high efciency and hence low ue gas temperature of the boiler.
● Advise the user of the precautions necessary to prevent
damage to the system, boiler and the building, in the event of the heating system being out of use during frost or freezing conditions.
● Advise the user that the permanent mains electrical supply
SHOULD NOT be switched off, as the built in frost protection and pump saver program will not operate.
● Advise the User if the mains electricity and gas are to be
turned off for any long periods during severe weather, it is recommended that the whole system, including the boiler, should be drained to avoid the risk of freezing. NOTE: Sealed System: Contact your installation/servicing
company as draining, relling and pressurising MUST be
carried out by a competent person approved at the time by the Health and Safety Executive.
● Leave these instructions and the ‘Benchmark’ Installation,
Commissioning and Service Record with the user.
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MAINTENANCE
IMPORTANT NOTES:
1. To ensure the continued efcient 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. Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the gas supply should be turned off at the gas isolation valve.
4. When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and
performance specication 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 13.
6. After servicing, complete the relevant Service Interval Record section of the Benchmark Checklist located in the inside back pages of this document.
12 Servicing
General Inspection
Prior to, during servicing and after any maintenance or changed parts, the following must be checked.
● The integrity of the ue system and ue seals.
● The integrity of the appliance combustion circuit and
relevant seals.
● Electrical, gas and water connections.
● System pressure.
● the combustion performance, refer to the following procedure.
● The operational gas inlet pressure and gas rates, refer to the
commissioning section paragraph 11.7. Correct any fault before continuing.
COMPETENCY TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE
NOTE: BS 6798: 2009 Specication for installation and
maintenance of gas-red boilers of rated input not exceeding
70kW net advises that:
● The person carrying out a combustion measurement must be assessed as competent in the use of a ue gas analyser
and the interpretation of the results.
● The ue gas analyser used should be one meeting the
requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturers’ requirements.
● Competence can be demonstrated by satisfactory completion
of the CPA1 ACS assessment, which covers the use of electronic portable combustion gas analysers in accordance with BS 7967, parts 1 to 4.
● Ensure that the gas analyser is set to the correct fuel
setting.
● Select the “
function by pressing the “Mode” button repeatedly, refer to
commissioning section.The boiler should re automatically. NOTE: Safe combustion can only be veried by measuring CO/
CO2 ratio. This must not exceed the value shown in the table below.
MODEL CHECK SETTING CO/CO2
24cx 8.8 to 9.8 9.2 +0.3
30cx 8.8 to 9.8 9.1 +0.3
35cx 8.8 to 9.8 8.8 +0.3
”, constant central heating with DHW
G20 BURNER % CO2
ratio
0.004
- 0.3
0.004
- 0.3
0.004
- 0.3
COMBUSTION CHECK AND SETTING THE AIR/
GAS RATIO VALVE
● Remove the front casing panel, see diagram 12.2 and hinge
down the control box. Taking care not to touch any internal components, proceed as follows:
● Connect the CO2 combustion analyser to the relevant test
point, see diagram 12.1.
15445
Diagram 13.1
1. Maximum Rate Check and Adjustment
NOTE: To verify the maximum gas rate CO2 setting the
appliance must be checked at the maximum rate rst. 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. Pressing the mode button when “Hi” is selected will force the boiler
to maximum rate, the display will ash between “Hi” and the
“default display” this will indicate the boiler has been forced to maximum. Wait until the CO2 value is stable and check that
the value is within the range specied in table in the “check”
column. If the combustion reading is not within the acceptable values
AND the integrity of the complete ue system and combustion circuit seals have been veried and the inlet gas pressure (and gas rate) have been veried, then, it will necessary to
adjust the combustion rate of the appliance. NOTE: Adjustment is made by turning the gas valve throttle
an ⅛ of a turn, waiting 1 minute to allow the appliance to
stabilise before checking or making further adjustments.
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MAINTENANCE
FRONT PANEL
SECURING SCREWS
● Rotate the “throttle”(anti-clockwise to increase), to the
required CO2, refer to diagram 12.4 and the “SETTING” column in the table.
● Exit the forced rate function, press the “mode” and “+”
buttons simultaneously, this will reset the boiler to the default display. Now proceed to check the minimum rate adjustment.
2. Minimum Rate Check and Adjustment
● Now check the minimum gas rate CO2 setting: Press
and release the “reset” button on the controls fascia, then immediately press and hold in either of the “+” buttons. After approximately 5 seconds “Hi” will be displayed. Pressing the “+” or “-” buttons will toggle between “Hi” and “Lo”. Press the mode button when “Lo” is selected, this will force the boiler to
minimum rate and the display will ash “Lo”, indicating the boiler
is operating at minimum.
● Wait until the CO2 value is stable and check that the value is within the range specied in table in the “check” column.
If adjustment is necessary, proceed as follows: NOTE: Adjustment of the CO2 at minimum rate is very
coarse and should not be adjusted more than an ⅛ of
a turn at a time. Wait 1 minute to allow the appliance to stabilise before checking or making further adjustments.
● Gradually rotate the “offset adjustment” (anti-clockwise to
decrease) to the required CO2, refer to diagram 12.4 and the “SETTING” column in the table.
● Exit the minimum rate function, press the “mode” and “+”
buttons simultaneously, this will reset the boiler to the default display.
All routine servicing requirements can be achieved by the removal of the front panel, see diagram 12.2. Position the control box into the service position, see diagram 12.3. Before commencing with a service or replacement of parts. The boiler should be isolated from the electrical and gas supplies.
13093
3. Re-Check CO2 and check the CO/CO2 combustion ratio.
● Re-check the maximum and minimum CO2 values to ensure
that they are within the “setting” limits in the table then check the CO/CO2 combustion ratio does not exceed the value in the CO/CO2 column of the table. If the CO/CO2 ratio exceeds the value in the table, a complete servicing of the appliance will be necessary, refer to section 12.1. If the CO2 and the CO/CO2 ratio falls within the tolerances quoted, exit the function press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display. Remove the analyser probe and replace the cap on the sampling point, replace the controls fascia, inner and front casing panels. IMPORTANT: Remember to replace the sample point cap on completion of the test.
GAS RATE CHECK
Check the gas rates as described in the commissioning section.
COMPLETION
If it is not possible to achieve the required results for either the combustion or gas rates, it will be necessary to complete a full service of the appliance and then repeat the combustion check procedure. If after servicing and adjustment of the appliance the combustion values are still unacceptable and after further remedial work has been carried out, the appliance must be disconnected until the CO/CO2 ratio is acceptable. Advice can be sought from the Glow-worm Technical Helpline.
Diagram 12.2
13554
Diagram 12.3
12776
12.1 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.
- 30 -
Diagram 12.4
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MAINTENANCE
12.2 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 ue hood up to disengage from
the sump, see diagram 12.5.
To remove, swivel ue hood 90
diagram 12.5. Check seal for wear or damage and replace if necessary.
IMPORTANT: Do not allow xings, nuts, screws, etc. to fall into the open ue hood sump, use a temporary cover whilst
removing any parts. Disconnect the spark electrode plug and earth lead. Remove the two securing screws and withdraw the spark electrode carefully from the combustion chamber, see diagram 12.6. Inspect the tips for damage. Clean away any debris and check the spark gap is 4mm. Check the electrode gasket for signs of damage and replace if necessary.
o
and pull down and out, see
12.3 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 12.7.
The Silencer (front) is a push t, so there is no need for tools to remove or t, see diagram 12.8.
Release the igniter unit support bracket, see diagram 12.9. Remove the fan retaining bracket. To ease removal of the securing nut from the fan retaining
bracket, a at bladed screwdriver can be used in the position
shown and gently levered down as indicated, see diagram
12.10. Remove the fan and gas valve assembly.
The silencer (rear) is a push t so no tools are required for its removal or tting, see diagram 12.9.
Check the spark electrode gap is 4mm. Clean and adjust as necessary, see diagram 12.6. It should not be necessary to remove the spark electrode from the burner during servicing.
Remove the anged nuts and studs that secure the burner, note
that two studs at the rear also hold the fan clamping bracket, see diagram 12.12. Clean the burner with a soft brush taking great care not to damage the surface of the burner. DO NOT use wire or sharp instruments to clean the mesh of the burner. NOTE: The burner gasket should be inspected but will not need replacing unless there are signs of wear or damage.
Follow the tightening sequence when re-tting the burner, see
diagram 12.12.
15585
15586
Diagram 12.5
14408
12.4 Heat Exchanger
NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component.
Remove loose debris from inside the heat exchanger using a soft brush and vacuum cleaner.
Carefully ush by spraying water into the heat exchanger, any
remaining debris should pass through the condensate trap (Ensure the water is kept away from electrical components).
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Diagram 12.6
- 31 -
MAINTENANCE
SECURING
SECURING
UNIT
CONNECTION
ELECTRICAL CONNECTIONS
SCREW (3)
ELECTRICAL CONNECTION (removed)
GAS VALVE
TUBING NUT
GAS PIPE
Diagram 12.7
14079
13128
IGNITER
EARTH
14409
NUT
SUPPORT
BRACKET IGNITION LEAD
SPADE CONNECTOR
Diagram 12.9
14081
Diagram 12.8
Diagram 12.10
14288
Diagram 12.11
- 32 -
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MAINTENANCE
A
SECURING NUTS (6)
BURNER
FAN CLAMPING BRACKET
12.5 Condense Trap and Siphonic Drain
The condense trap and siphonic drain does not normally need
servicing unless material deposits exceed beyond the service ll
level, see diagram 12.13. To clean the condense trap remove the sump and rinse with water.
12.6 Casing panel seal check
NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component.
Check the condition of the seal and replace if worn or damaged. To replace remove the old seal and thoroughly clean the casing surfaces. Fit the new seals, these are supplied to the correct lengths and are in four pieces, for use on the sides, top and bottom.
12.7 Service Completion
Re-check the combustion as described at the beginning of this section. On completion of the service the “Benchmark” Service Record should be completed.
14410
14397
13929
CONDENSE TRAP
ND SIPHONIC DRAIN
Diagram 12.12
SECURING SCREW
SUMP
SERVICE FILL LEVEL
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Diagram 12.13
- 33 -
MAINTENANCE
13 Fault Finding
13.1 Preliminary fault nding
The following checks should be performed before proceeding
onto specic 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. For access remove and open the electrical cartridge, see diagrams 10.4. and 10.1. Test at the ‘L’ and ‘N’ terminals on the installer interface, refer to diagrams 10.1 and 13.4.
• Check the electrical installation and appliance, carry out tests for earth continuity, polarity, short circuit and resistance to earth, using a suitable multimeter. An aid to test Remove the front casing panel, see diagram 13.1 and hinge down the control box. Unclip the rear cover to gain access to the main PCB. Carry out the tests at connector plug X17, see diagram
13.2. Check chassis earth at a bare metal point on the boiler.
• Check that there is a gas supply to the boiler and the gas service isolation valve is turned on, see diagram 8.2.
• Check pressure at the gas service isolation valve, refer to section 11.7.
• Check that the heating system pressure indicates at least
1mb, if not, ll and vent the system as described in section
11.2.
• Check that all external controls are on.
• Check the functional ow diagram, 13.5.
13093
Diagram 13.1
13845
13.2 Fault Codes
Fault codes take priority over all other display functions in the event of a fault occuring, refer to diagram 13.6. If multiple faults occur the codes will be displayed for approx. 2 seconds, alternatively.
13.3 Fault Memory
The Fault memory stores details of the ten most recent faults.
To access this menu, refer to diagram 13.3: a) Press and hold ‘MODE’ and ‘-’ buttons for 5 seconds.
b) The display will stop ashing and alternate between the fault
memory number and the fault code. c) Press ‘+’ button to scroll through the fault memory (Position 1 is most recent), see fault codes. To exit this menu, press the ‘MODE’ button.
13.4 Diagnostic Menu
The Diagnostic Menu provides the ability to view and change certain parameters. See diagram 13.7 for available parameters.
13.5 Status Codes
The status codes provide information about the current operating condition of the boiler and can be accessed through the diagnostic display, refer to diagram 13.8.
Diagram 13.2
14028
- 34 -
Diagram 13.3
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MAINTENANCE
14516
0020107232_03 - 12/14 - Glow-worm
MODE
Diagram 13.4
- 35 -
MAINTENANCE
CENTRAL HEATING
13012
DHW
13015
- 36 -
Diagram 13.5
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FAULT CODES
MAINTENANCE
14027
0020107232_03 - 12/14 - Glow-worm
Diagram 13.6
- 37 -
MAINTENANCE
State list - To access the state lists the ‘-’ button must be pressed for longer than 5 seconds until it begins to ash ‘S’ and
then a number to indicate the state. The state numbers are given below.
STATE LISTS
Central heating mode Description
S.00 no heating required S.01 fan pre-run S.02 pump pre-run S.03 ignition S.04 burner on S.05 pump / fan overrun S.06 fan overrun S.07 pump overrun S.08 Anti cycling period
NORMAL OPERATING STATE FOR CH MODE
Domestic hot water mode
S.10 domestic hot water demand S.11 fan pre-run S.13 ignition S.14 burner on S.15 pump / fan overrun S.16 fan overrun S.17 pump overrun
NORMAL OPERATING STATE FOR DHW MODE
Preheat mode
S.20 domestic hot water cycling mode active S.21 fan pre-run S.22 Pump pre run S.23 ignition S.24 burner on S.25 pump / fan overrun S.26 fan overrun S.27 pump overrun S.28 Anticycling period
NORMAL OPERATING STATE FOR PRE-HEAT MODE
13011
Special cases of status messages
S.30 No Heating demand from external controls 230V Check wiring in external controller.
Check wiring at Installer Interface.
S.31 summer mode Check CH setpoint / Check external controls S.32 Antifreeze active – fan speed variation too high Check fan connection. waiting during blocking function S.34 frost protection active (Priority 4) Te mperature below 8 connection if this is not true. S.36 No Heating demand from external controls 24V Check wiring in external controller.
Check wiring at Installer Interface.
S.42 Accesory Module is blocking burner operation Check accessory module. S.53 waiting time: temperature difference flow
- return sensor too high (Check thermistor fit)
S.54 waiting time: no water in system, temperature (gradient error) rise flow / return sensor too high
S.76 Waiting period – pressure sensor Check system pressure - default display. S.96 Return-Sensor check is running, demand Check return thermistor connection to pipe. (DHW or heating) is blocked Check harness connection to thermistor. S.97 Water pressure sensor check is running, Check connection to pressure sensor. demand (DHW or heating) is blocked Check pump has not seized. S.98 Flow / Return - sensor check is running, demand (DHW or heating) is blocked.
Check flow & return thermistor connections to pipes. Check harness connection to thermistor. Check harness wires are not trapped between any internal components.
Check flow & return thermistor connections to pipes. Check harness connection to thermistor. Check harness wires are not trapped between any internal components.
Check flow & return thermistor connections to pipes. Check harness connection to thermistor. Check harness wires are not trapped between any internal components.
O
C - check thermistor
- 38 -
Diagram 13.7
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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 ash between ‘L1’ and a number. ‘L1’ indicates you have level 1 access, the number indicates
the diagnostic number below. Use the ‘+’ and ‘-’ to cycle through the selections below. To select a diagnostic number press the ‘MODE’ button when the correct number is selected. The display will show the parameter value of the diagnostic number selected. To return to the diagnostic number selector simply press the ‘MODE’ button. To change the parameter use the + or
- buttons. Once the value has been changed it must be saved by holding the ‘MODE’ button for approximately 5 seconds. This will return to the diagnostic number selector.
DIAGNOSTIC CODES - LEVEL 1 Installer Access
14512
Indicates read and write function - all other diagnostics are read only
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Diagram 13.8
- 39 -
MAINTENANCE
14 Replacement of Parts
14.1 General
Replacement parts that have associated components that need replacing on removal, i.e. ‘O’ ring, seals, gasket, etc., will be
supplied and should be tted.
Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety
Executive. Before replacing any parts of the boiler it 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
14.1. Unless stated otherwise parts are replaced in the reverse order to removal. After replacing any parts always test for gas tightness and if necessary carry out functional test of the controls.
Boiler Access
For replacement of parts the front casing of the boiler will need to be removed. To remove undo the two screws on the underside of the front casing and lift off.
If the appliance site situation has sufcient side clearances
the side panels can be hinged sideways and removed to aid replacement of parts. To hinge a side panel undo and remove the four screws securing each side panel to the boiler, two below and two at the top.
Draining of Boiler Heating Circuit
Drain down the Heating Circuit of the boiler only, by closing the
heating ow 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. After replacing parts, close the drain valve and remove the
hose. Open the heating ow and return isolating valves and rell, vent and pressurise the heating circuit, refer to section 11.
Check for leaks.
13931
Diagram 14 .1
15584
Draining of Boiler Hot Water Circuit
Drain the Domestic Hot Water circuit by closing the cold-water isolation valve on the wall mounting jig, see diagram 14.1. Open one or more hot water taps to drain the hot water circuit. After replacing parts open the cold-water isolation valve and slowly open a hot water tap to remove air. Close the hot water tap and check for any leaks.
14.2 Igniter Unit
For access, refer to section 14.1. Remove ignition lead and electrical connections then remove igniter unit by removing two securing screws, see diagram 12.9.
14.3 Ignition Lead
For access, refer to section 15.1. Pull the spark plug style connector off the spark electrode and the spade connector connected to the igniter unit, see diagram
12.6.
Diagram 14.2
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MAINTENANCE
14.4 Gas Valve
Remove the three securing screws, holding the gas valve to the fan, see diagram 12.7. Remove the gas valve.
After re-tting check the combustion CO2 and adjust if
necessary, refer to section 12, Combustion Check. After assembly test for gas tightness and purge in accordance with the current issue of BS6891or in IE, the current edition of I.S.813 “Domestic Gas Installations”.
14.5 Flue Hood
For access, refer to section 14.1.
Pull the ue hood securing clips away from the ue hood sump and push ue hood up slightly towards ue hood top, see
diagram 12.5.
To remove swivel ue hood 90° and pull down and out towards
front of boiler.
14.6 Fan
For access, refer to section 13.1. Remove the gas valve as described in the relevant parts of section 14.8. Remove the securing nut holding the fan retaining bracket, lift front of bracket away from stud and pull forward to release the fan, see diagram 12.10, check and replace any seals or gaskets if necessary.
14.10 Spark Electrode
For access, refer to section 14.1. Remove the spark plug lead and earth lead. Remove the two securing nuts, see diagram 12.6. Withdraw the spark electrode by slowly pulling up and leaning it forward towards the centre of the heat exchanger to ensure that the electrode does not foul on the hole in the burner casing. Check spark gap.
14.11 Burner
For access, refer to section 14.1.
Remove igniter unit, ue hood, fan and gas valve assembly and
spark electrode lead, refer to relevant sections.
Remove the anged nuts and studs that secure the burner, note
that two studs at the rear also hold the fan clamping bracket, see diagram 12.12. NOTE: The burner gasket should be inspected but will not need replacing unless there are signs of wear or damage.
IMPORTANT: Do not allow xings, nuts, screws, etc. to fall into the open ue hood sump, use a temporary cover whilst
removing any parts.
14.7 Expansion Vessel
For access, refer to section 14.1. Drain the boiler heating circuit, refer to section 14.1. Undo the coupling at the base of the vessel, see diagram 14.2. The expansion vessel can now be removed by sliding it forward clear of its support guides.
When re-tting a new gasket will be required between the
expansion vessel and coupling.
Rell, vent and pressurise the boiler.
Check for leaks.
14.8 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 12.7. Remove the securing nut holding the fan retaining bracket, press down on burner to ease removal of securing nut. Slide out the fan retaining bracket. Lift front of bracket away from stud and pull forward to release the fan, see diagram 12.10. Lift fan/gas valve assembly up and forward away from locating studs. Remove fan gasket and replace if necessary. To replace the fan and retaining bracket correctly, insert into slots on fan clamping bracket, see diagram 12.12 and locate onto lugs on the burner.
13027
14.9 Silencer assembly (rear)
For access, refer to section 14.1. Remove the fan/gas valve assembly, see relevant sections. Pull Silencer rear away from fan/gas valve assembly.
The rear silencer is a push t so no tools or xings are required for its removal or tting, see diagram 14.11.
0020107232_03 - 12/14 - Glow-worm
Diagram 14.3
- 41 -
MAINTENANCE
14.12 Silencer Assembly (front)
For access, refer to section 14.1. Pull forwards to remove.
The silencer is a push t so no tools or xings are required for its removal or tting, see diagram 12.8.
14.13 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 12.13. 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 indicated, see diagram
12.13, toward the unlock symbol and carefully pull down clear of the condense drain. Remove any solids found in the condense trap. Flush water through the trap to remove any remaining solids. Check for any debris in the outlet pipe of the condensate drain and clean as necessary.
Reassemble and ret the condense trap.
14.14 Heating Flow Thermistor
For access refer to section 14.1.
Remove the silencer front, fan/gas valve assembly and ue
hood for access. See relevant sections. Refer to diagram 14.3. Remove the electrical connections from the thermistor.
Remove the retaining clip from the ow pipe.
Remove the thermistor from the retaining clip. Note that the polarity of the wiring to thermistors is unimportant.
14.18 Domestic Hot Water Thermistor
For access, refer to section 14.1. Refer to diagram 14.5. Remove the electrical connections from the thermistor. Remove the retaining clip from the DHW pipe. Remove the thermistor from the retaining clip. Note that the polarity of the wiring to thermistor is unimportant.
14.19 Plate-to-Plate Heat Exchanger
For access, refer to section 14.1. Drain the boiler heating circuit, refer to section 14.1. Refer to section 14.3 and drain the boiler hot water circuit. Refer to diagram 14.6. Remove the gas supply pipe from the gas service isolation valve and the gas valve, refer to relevant parts of section 14.4. Remove the condensate trap as described in section 14.13. Remove the four screws securing the plate-to-plate heat exchanger to the hydroblock, see diagram 14.6. Remove the plate-to-plate heat exchanger. When replacing the plate-to-plate heat exchanger ensure that
the four rubber sealing washers are tted into the hydroblock. NOTE: The plate-to-plate heat exchanger only ts one way
round.
Rell, vent and pressurise the boiler.
Open the cold-water isolation valve and slowly open a hot water tap to remove air. Close the hot water tap and check for any leaks. Open the heating circuit isolation valves, re-pressurise the system as necessary, refer to diagram 14.1.
14.15 Heating Return Thermistor
For access, refer to section 14.1. Refer to diagram 14.4. 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. Note that the polarity of the wiring to thermistor is unimportant.
13063
13060
- 42 -
Diagram 14.4
Diagram 14.5
0020107232_03 - 12/14 - Glow-worm
MAINTENANCE
14.20 Pump (head only)
For access, refer to section 14.1. Refer to section 14.1 and drain the boiler heating circuit. Refer to diagram 14.7. Remove the four cap head screws. Carefully remove the pump head together with cable. Do not strain cable. Support the pump head, unscrew cable cover at the side of pump head and remove. Disconnect wiring from pump head.
Reconnect wiring to new pump head and t cover.
Fit the new pump head with ‘O’ ring.
Rell, vent and pressurise the boiler and check for leaks.
14.21 Safety Discharge Valve
For access, refer to section 14.1. Refer to section 14.1 and drain the boiler heating circuit. Refer to diagram 14.8. 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.
Rell, vent and pressurise the boiler and check for leaks.
14.22 Automatic Air Vent
For access, refer to section 14.1. Refer to section 14.1 and drain the boiler heating circuit. Refer to diagram 14.9. Remove the retaining clip to release the automatic air vent. Fit the new automatic air vent and ‘O’ ring ensuring the vent cap is left loose.
Rell, vent and pressurise the boiler and check for leaks.
15587
Diagram 14.7
12667
Diagram 14.6
14031
Diagram 14.8
12669
Diagram 14.9
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- 43 -
MAINTENANCE
14.23 Flow Sensor
For access, refer to section 14.1. Refer to section 14.1 and drain the boiler hot water circuit. Refer to diagram 14.10. Undo the brass securing nut on the domestic cold water return pipe.
Remove the securing clip between the hydroblock and the ow
sensor.
Remove the electrical connection to the ow sensor. Remove the securing clip holding the brass elbow to the ow
sensor.
Partially withdraw the ow sensor to allow removal of the
electrical connection before full removal of the sensor.
Remove ow sensor.
Fit new ‘O’ rings.
After replacing the ow sensor, open the cold-water isolation
valve and slowly open a hot water tap to remove air. Close the hot water tap and check for any leaks.
14.24 Three Way Valve
For access, refer to section 14.1. Refer to section 14.1 and drain the boiler heating circuit and the boiler hot water circuit. Refer to diagram 14.11. Undo the nut retaining the heating return isolation valve to the
xing jig. Be careful not to lose the sealing washer. Undo the securing nut on the underside of the xing jig and pull
the pipe away from the three-way valve assembly. Fully remove the three securing screws and pull the three­way valve assembly towards the left to disengage from the hydroblock. (Ensure that the original o-ring has not been retained in the hydroblock.) Fit the new three-way valve assembly.
Reassemble, rell, vent and pressurise the boiler and check for
leaks.
13064
Diagram 14.10
12668
- 44 -
Diagram 14.11
0020107232_03 - 12/14 - Glow-worm
MAINTENANCE
14.25 Heat Exchanger
For access, refer to section 14.1. Refer to section 14.1 and drain the boiler heating circuit and the boiler hot water circuit.
Remove the silencer front
Pull forwards to remove.
The silencer is a push t so no tools or xings are required for its removal or tting, see diagram 12.8.
Remove the ue hood front
Ease the securing clips away from the sump to release the
retaining catch then push the ue hood up to disengage from
the sump, see diagram 12.5.
To remove, swivel ue hood 90° and pull down and out, see
diagram 12.5.
Remove the igniter unit with support bracket
Disconnect the electrical connections and ignition lead. Release the igniter unit support bracket. Remove the igniter unit assembly, see diagram 12.9.
Remove the gas valve/fan
Disconnect the tubing nut at the gas valve, see diagram 12.7. Remove the fan retaining bracket, see diagram 12.10. To ease removal of the securing nut from the fan retaining
bracket, a at bladed screwdriver can be used in the position
shown and gently levered down as indicated. Remove the spark electrode plug and earth connection. Remove the fan and gas valve electrical connections. Remove the fan and gas valve assembly.
Remove the condensate trap
Remove the drain outlet pipe from the base of the trap, see diagram 14.1. Remove the condensate drain securing screw and carefully pull the trap forward, see diagram 12.13.
Remove the heat exchanger
Remove the retaining clip, see diagram 14.12, which secures
the ow pipe brass elbow into the hydroblock. Remove the retaining clip, which secures the ow pipe into the anged
elbow in the top right hand corner of the heat exchanger, see diagram 14.14. Remove the left hand side panel to aid removal of the copper
ow pipe. Note that the minimum clearance from the side panel is 5mm. Remove the ow pipe. Undo the union nut connecting the ow pipe to the pump. Remove the retaining clip from the anged elbow at the right
hand bottom of the heat exchanger, see diagram 14.13. Remove screws securing the heat exchanger, one on top and one underneath the heat exchanger, see diagram 14.14. Lift up heat exchanger slightly to disengage it from its hanging bracket. Remove the heat exchanger by pulling forward and tilting backwards to ease removal complete with sump, return pipe
and anged elbows. Remove the return pipe then discard the heat exchanger complete with sump and anged elbows.
RETAINING CLIP
FLANGED ELBOW
15589
FLOW PIPE
Diagram 14.12
15558
RETAINING CLIP
FLOW PIPE
UNION NUT
Diagram 14.13
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- 45 -
MAINTENANCE
RETAINING CLIP
14414
14399
Diagram 14.14
Remove the burner
Remove the anged nuts and studs that secure the burner, note
that two studs at the rear also hold the fan clamping bracket, see diagram 14.15. Taking great care not to damage the surface of the burner. NOTE: Replace the burner gasket and follow the tightening
sequence when re-tting the burner, see diagram 14.15. NOTE: Fit all replacement gaskets and seals when re-tting
parts.
Filling the boiler heating circuit/domestic hot water system and re-pressurising
After replacing parts open the cold-water isolation valve and slowly open a hot water tap to remove air. Close the hot water tap and check for any leaks. After replacing parts, close the drain valve and remove the
hose. Open the heating ow and return isolating valves and rell, vent and pressurise the heating circuit, refer to Section 11,
Commissioning.
- 46 -
Diagram 14.15
0020107232_03 - 12/14 - Glow-worm
MAINTENANCE
14.26 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 14.16. Unclip user interface and remove. For replacement, see diagram 14.17 and ensure that the user
interface connection cable is retted. NOTE: When re-tting any of the control boards make sure you
support the control box to avoid straining hinges as you push down and clip back into place.
14.27 Control Box
For access, refer to section 14.1. Hinge down the control box and unclip the rear cover to gain access. Remove relevant electrical connections from main PCB and grommets from the control box. IMPORTANT: Support the control box whilst undoing the hinges. Remove the hinge securing screws accessed from beneath the boiler and remove the control box, see diagram 15.18.
14.29 Installer Interface Electrical Cartridge
Remove the Installer Interface securing screw accessed from beneath the boiler. Carefully pull down the electrical cartridge, disconnect the cables.
13001
14.28 Fuse - Main PCB - Control Box
For access, refer to section 14.26. The fuse is located at the top left hand corner of the main PCB, see diagram 14.16.
13003
Diagram 14.17
13004
0020107232_03 - 12/14 - Glow-worm
Diagram 14.16
Diagram 14.18
- 47 -
MAINTENANCE
15 Spare Parts
When ordering spare parts, contact Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet. Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gas also quote the G.C. number of the part.
Key No. Part No. Description GC No
1 0020020734 Fan H42723 2 0020020763 Igniter unit H42773
3 0020020781 Heating ow & return thermistor (2) H42792
4 0020014160 DHW thermistor H36325 5 0020020735 Gas valve 24cx / 30cx H42724 5 0020059600 Gas valve 35cx H69002 6 0020020731 Electrode H42720 7 0020020728 Burner 24cx / 30cx H42718 7 0020059602 Burner 35cx H69008 8 0020023826 User interface H42784 9 0020014402 Plate to plate heat exchanger 24cx H43160 9 0020014402 Plate to plate heat exchanger 30cx H43160 9 0020014403 Plate to plate heat exchanger 35cx H69009 10 0020014171 Pump H42760 11 0020014174 Flow sensor H43155 12 0020023825 Main PCB H42783 13 0020079644 Water pressure sensor H80-150
14507
- 48 -
Diagram 15.1
0020107232_03 - 12/14 - Glow-worm
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. Avoid upper body/top heavy bending - do not lean forward/sideways. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip. Always use assistance if required.
Removal of carton from delivery van
Recommend 2 person lift or 1 person with use of sack truck. If 1 person is performing lift, straddle the load, tilt and place carton into position on truck. Recommend secure appliance onto truck with suitable straps. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. If 2 persons performing lift, ensure co-ordinated movements during lift. Always use assistance if required.
Carriage of carton from point of delivery to point of installation –
ground oor.
Recommend 2 person lift or 1 person with use of sack truck. If 1 person is performing lift, straddle the load, tilt and place carton into position on truck. Recommend secure appliance onto truck with suitable straps. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. If 2 persons per­forming lift, ensure co-ordinated movements during lift. Clear the route before attempting the lift. If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip. Ensure safe lifting techniques are used – keep back straight – bend using legs. Do not twist – repo­sition feet instead. Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs. Always use assistance if required.
Carriage of carton from point of delivery to point of installation –
rst or higher oor, cellar.
Recommend 2-person lift or 1 person with use of sack truck. If 1 person is performing lift, straddle the load, tilt and place carton into position on truck. Recommend secure appliance onto truck with suitable straps. Ensure safe lifting techniques are used – keep back straight – bend us­ing legs. Keep load as close to body as possible. If 2 persons perform­ing lift, ensure co-ordinated movements during lift. Avoid upper body/top heavy bending - do not lean forward/sideways. Clear the route before attempting the lift. If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip. Ensure safe lifting techniques are used – keep back straight – bend using legs. Do not twist – reposition feet instead. Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs. Always use assistance if required.
Carriage of carton from point of delivery to point of installation – roofspace.
Recommend 2-person lift. Ensure co-ordinated movements during lift. Avoid upper body/top heavy bending - do not lean forward/side­ways. Clear the route before attempting the lift. Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs. When transferring appliance into roofspace, recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and support appliance. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. Always use assistance if required. It is assumed safe access,
ooring and adequate lighting are provided in the roof space. It is
recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access,
stability of ooring, lighting and other factors, and appropriate measures
taken.
Unpacking of appliance from carton.
Recommend 2 persons unpack appliance from carton. Always keep working area clear. Cut the carton straps, lift carton up and slide over
polystyrene end packs. Remove top polystyrene pack with ttings.
Positioning of Appliance for Final Installation – no obstructions.
Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain rm
grip on front and sides of appliance, lift upwards, ensure stable bal­ance achieved and lift upwards to position in place on bracket. Ensure safe lifting techniques are used – keep back straight – bend using
legs - when lifting load from oor level. Do not twist – reposition feet
instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Ensure co-ordinated movements to ensure equal spread of weight of load. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – above worktop, foreseeable obstructions etc.
Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain rm grip
on front and sides of appliance, lift upwards, onto worktop if practicable. Ensure stable balance achieved and lift upwards to position in place on
bracket. If 2 persons positioning onto bracket obtain rm grip at front and
sides/base of boiler. Ensure co-ordinated movements during 2 person lifts to ensure equal spread of weight of load. Ensure safe lifting tech­niques are used – keep back straight – bend using legs - when lifting
load from oor level. Do not twist – reposition feet instead. Keep boiler
as close as possible to body throughout lift to minimise strain on back. Avoid upper body/top heavy bending - do not lean forward/sideways. Al­ways use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – within compartment etc. restricting installation.
Recommend 2 persons lift appliance to position into place, space per­mitting. Fit bracket securely onto wall before lifting appliance into posi-
tion. Obtain rm grip on front and sides of appliance, lift upwards, onto
worktop if practicable. Ensure stable balance achieved and lift upwards to drop into place onto bracket. If 2 persons positioning onto bracket
obtain rm grip at front and sides/base of boiler. Ensure co-ordinated
movements during 2 person lifts to ensure equal spread of weight of
load. If 1 person positioning onto bracket recommend obtain rm grip
supporting base of boiler. Ensure safe lifting techniques are used – keep
back straight – bend using legs - when lifting load from oor level. Do
not twist – reposition feet instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – in roof space re­stricting installation.
Recommend 2 persons lift appliance to position into place, space permit­ting. Fit bracket securely onto wall before lifting appliance into position. Obtain rm grip on front and sides of appliance, lift upwards, ensure sta­ble balance achieved and lift upwards to drop into place onto bracket. If 2
persons positioning onto bracket obtain rm grip at front and sides/base
of boiler. Ensure co-ordinated movements during 2 person lifts to ensure equal spread of weight of load. If 1 person positioning onto bracket rec-
ommend obtain rm grip supporting base of boiler. Ensure safe lifting
techniques are used - keep back straight – bend using legs - when lifting
load from oor level. Do not twist – reposition feet instead. Keep boiler as
close as possible to body throughout lift to minimise strain on back. Al­ways use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance. It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the
area to take into account access, stability of ooring, lighting and other
factors, and appropriate measures taken.
0020107232_03 - 12/14 - Glow-worm
- 49 -
THE AIR GAS RATIO VALVE IS FACTORY
SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING
CONTACT WITH THE MANUFACTURER.
If any such adjustment is recommended and
further checking of the boiler is required the
installer/service engineer must be competent
to carry out this work and to use the flue gas
If the boiler requires conversion to operate with
a different gas family (e.g. conversion from
natural gas to LPG) separate guidance will be
provided by the boiler manufacturer
NOTE
analyser accordingly.
The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas
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. flue lengths have not been
exceeded and all guidance has been followed (e.g. Gas Safe Technical Bulletin TB008).
Prior to its use, the flue gas analyser should have been maintained and calibrated as specified by the
The flue gas analyser should be of the correct type, as specified by BS 7967
manufacturer. The installer must have the relevant competence for use of the analyser.
Check and zero the analyser IN FRESH AIR as per analyser manufacturer’s instructions.
PRIOR TO CO AND COMBUSTION RATIO CHECK
supply pressure/rate checked as required prior to commissioning.
In accordance with boiler instructions, set boiler to operate at max. rate
(full load condition). Allow sufficient time for combustion to stabilise.
NOTE - Do not insert analyser probe during this period to avoid
CARRY OUT FLUE INTEGRITY CHECK USING ANALYSER
Insert analyser probe into air inlet test point and allow readings to stabilise.
NOTE - where no air inlet test point is provided then a flue integrity check
with the analyser is not possible. The installer should verify that flue
integrity has been visually checked in accordance with the yellow “Prior to
CO and combustion ratio check” box above before proceeding to the
“Check CO and combustion ratio at maximum rate” stage below.
SET BOILER TO MAXIMUM RATE
possible “flooding” of sensor.
Analyser readings indicate that combustion products and inlet air must be mixing. Further investigation of
Check that flue and flue terminal are not obstructed.
VERIFY FLUE INTEGRITY
the flue is therefore required.
Check that flue components are assembled, fixed
and supported as per boiler/flue manufacturer’s
instructions.
Is
20.6%
O
2
and
CO
< 0.2%
2
YES
NO
TURN OFF APPLIANCE AND CALL
MANUFACTURER’S TECHNICAL HELPLINE
COMMISSIONED UNTIL PROBLEMS ARE
Check all seals around the appliance burner,
internal flue seals, door and case seals.
FOR ADVICE.
THE APPLIANCE MUST NOT BE
IDENTIFIED AND RESOLVED.
Rectify where necessary.
Is
CO
less than
335ppm
and
ratio less
CO/CO
2
than 0.004
YES
NO
NO
20.6%
O
2
CO
Is
and < 0.2%
2
YES
CHECK CO AND COMBUSTION RATIO AT MAX. RATE
With boiler still set at maximum rate, insert analyser probe into flue gas
sampling point. Allow readings to stabilise before recording.
NOTE - If no flue gas sampling point is present and the correct procedure is
not specified in the manual, consult boiler manufacturer for guidance.
Is
NO
CO less than
350ppm and
ratio
CO/CO
2
less than 0.004
YES
In accordance with boiler instructions, set boiler to operate at minimum rate (to
minimum load condition). Allow sufficient time for combustion to stabilise.
NOTE - If manufacturer’s instructions do not specify how to set boiler to minimum
SET BOILER TO MINIMUM RATE
rate contact Technical Helpline for advice.
TURN OFF APPLIANCE AND CALL
MANUFACTURER’S TECHNICAL HELPLINE
COMMISSIONED UNTIL PROBLEMS ARE
COMMISSIONING CANNOT BE FULLY
COMPLETED, THE APPLIANCE MUST BE
DISCONNECTED FROM THE GAS SUPPLY IN
NOTE: Check and record CO and combustion ratio
at both max. and min. rate before contacting the
FOR ADVICE.
THE APPLIANCE MUST NOT BE
IDENTIFIED AND RESOLVED. IF
ACCORDANCE WITH THE GSIUR.
manufacturer.
NO
CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE
With boiler still set at minimum rate, insert analyser probe into flue gas sampling
NOTE - If no flue gas sampling point is present and the correct procedure is not
point. Allow readings to stabilise before recording.
specified in the manual, consult boiler manufacturer for guidance.
Is
CO less than
350ppm and
ratio
CO/CO
2
less than 0.004
YES
BOILER IS OPERATING SATISFACTORILY
Ensure test points are capped, boiler case is correctly replaced and
all other commissioning procedures are completed.
Complete Benchmark Checklist, recording CO and combustion ratio
no further actions required.
readings as required.
0020107232
GLOW-WORM
Nottingham Road, Belper, Derbyshire. DE56 1JT
Subject to engineering changes0020107232_03 - 12/14
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
www.glow-worm.co.uk
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