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Glow-worm 12hx Installation And Servicing Download Page 46

© Heating and Hotwater Industry Council (HHIC)

www.centralheating.co.uk

Benchmark Commissioning and 
Servicing Section

It is a requirement that the boiler is installed and commissioned to the 

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Summary of Contents for 12hx

Page 1: ...Installation and Servicing Condensing Boilers Flexicom hx 12 hx G C No 41 315 28 15 hx G C No 41 315 29 18 hx G C No 41 315 42 24 hx G C No 41 315 61 30 hx G C No 41 315 67 35 hx G C No 41 315 68 ...

Page 2: ... 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 Guarantee Registration 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 Benchm...

Page 3: ...nts 5 Boiler Design 6 Safety Devices 6 Servicing Maintenance and Spare Parts 6 Boiler Specification 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 19 Boiler Fixing 7 20 Gas Water and Appliance Connection 8 21 Condensate Connections 9 22 Electrical Connection 10 24 Commi...

Page 4: ...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 appr...

Page 5: ...e Current I E E Wiring Regulations Where no specific 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 ...

Page 6: ...of ice in the condense drain external to the house Release an ice blockage by the use of warm cloths on the pipe The boiler should then restart Condensate Drain A plastic drain pipe must be fitted 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 hous...

Page 7: ...0020107230_04 12 14 Glow worm TECHNICAL DATA 7 14730 1 Boiler Specification ...

Page 8: ...ions 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 13937 Diagram 2 1 ...

Page 9: ...e installations consideration should be given for the space required to insert the flue internally which may necessitate the clearance to be greater than those specified in diagram 3 1 3 3 Timber Frame Buildings If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 If in doubt seek advice from the lo...

Page 10: ... terminal must be exposed to the external air allowing free passage of air across it at all times Being a condensing boiler some pluming may occur from the flue 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 wind...

Page 11: ...l 300 I above adjacent ground or balcony level 300 J 2 from surface or a boundary facing the terminal 600 Position Position of the flue terminal mm L from opening door window in car port into dwelling 1200 M vertical from a terminal 1500 N horizontally from a terminal 300 Vertical flues P from another terminal 600 Q above roof level 300 R from adjacent opening window 1000 S from adjacent wall to f...

Page 12: ...e Max length Ø 60 100 8 m Ø 80 125 20 m Type Max length Ø 60 100 512 mm 4 2 3 Vertical concentric flue Ø 60 100 mm or Ø 80 125 mm C33 type installation a If the terminal is at less than 1 80 m from the ground you must install a terminal protection kit 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 L Each ti...

Page 13: ... and the manufacturers instructions supplied The appliance maximum flue length must be included when calculating the overall design of the flue system NOTE The horizontal flue terminal must be removed L B A 1 2 3 4 5 Key 1 Pressure balancing system 2 Air inlet pipe 3 Collector pipe 4 Boiler 5 Inspection hatch A Final storey B Ground floor Type Max length L Ø 60 100 8 m Each time an additional 90 b...

Page 14: ...in diagram 5 2 0 5 10 15 20 25 30 Flow Rate litres min 24kW 30kW Pressure Loss metres 15kW 35kW Diagram 5 2 14401 5 5 Bypass A system bypass is required and should be fitted at least 1 5 metres away from the boiler refer to the current issue of the central heating system specifications CHeSS 5 6 Water Treatment 5 6 1 General The Glow worm Flexicom range of boilers have an Aluminium alloy heat exch...

Page 15: ...lushing agent It is essential to drain and thoroughly flush the whole system to remove the flushing agent and debris It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances Close the drain cocks and refill with fresh water and a suitable inhibitor Vent any air from the boiler and system 5 6 3 Inhibiting the system Add a suitable inhibitor or combine...

Page 16: ...ent to atmosphere the installation must comply with the building regulations and the Water Supply water fittings regulations 1999 and water byelaws 2000 Scotland see also the current issue of BS5546 and BS6700 If fitting to an existing system the local authority should be informed 5 9 Vented DHW System General All domestic hot water circuits connections fittings must be in accordance with the rele...

Page 17: ...nsion Vessel A diaphragm type expansion vessel conforming to the current issue of BS4814 see also BS7074 Part 1 and 2 must be con nected at a point close to the inlet side of the circulating pump see the diagrammatic layout diagram 5 4 The expansion vessel volume depends on the total water system volume and the initial system design pressure For any system an accurate calculation of vessel size is...

Page 18: ...for replacing water loss from the sys tem using a make up bottle mounted in a position higher than the top point of the system connected through a non return valve to the return side of either the heating circuit or the hot water cylinder Alternatively provision for make up can be made using a filling loop 5 17 Filling a Sealed Water System Provision for filling the system at low level must be mad...

Page 19: ...ner then 149mm along the adjacent wall see diagram 6 2 For extended side flues the flue 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 flue passing through the wall at this angle a 125mm hole should be drilled ...

Page 20: ...he separate flue instructions and inserted through the hole in the wall before fitting the wall hanging bracket 7 2 Boiler Hanging IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following lift operation is deemed to be a one man lift refer to section 16 Manual Handling IMPORTANT Direct Rear Flue only The direct rear flue must be fitted before hanging the boiler refer...

Page 21: ... the meter should be inspected tested for tghtness and purged in accordance with the current issue of BS6891 and in IE the current edition of I S 813 Domestic Gas Installations Gas Connection Water Connections 12799 14507 8 2 Water Connections Provision is made for the water connections to be made from above the boiler see diagram 8 1 The position is shown on the wall template Flush out the domest...

Page 22: ...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...

Page 23: ...0020107230_04 12 14 Glow worm INSTALLATION 23 15826 Diagram 9 2 ...

Page 24: ...fied 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 fixed 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 fittings pack Remove the securing screw to open the cartridge see diagram 10 1 NOTE The...

Page 25: ... relevant sections of the Benchmark Checklist located in the inside back pages of this document 11 1 Preliminaries All Systems 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 in accordance with the current issue of BS6798 Make sure that the system has been thoroughly flushed out with cold ...

Page 26: ...n will commence Diagram 11 2 14513 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 Press and hold the Mode button of the boiler user controls for 2 seconds the Central Heating symbol will flash Use the SELECTOR b...

Page 27: ...he drain tap at the lowest part of the system Fill and vent the system as described previously in section 11 2 Lock or remove the handle from controls valve if fitted Adjust the boiler temperature controls and any system controls to their required settings 11 8 Completion Ensure that the magnetic lighting instruction label is placed on the surface of the boiler casing GB It is a requirement that t...

Page 28: ... use of a flue gas analyser and the interpretation of the results The flue 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 accordan...

Page 29: ...ill reset the boiler to the default display 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 ...

Page 30: ...valve and electrical connections see diagram 12 7 The Silencer front is a push fit so there is no need for tools to remove or fit 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 flat bladed screwdriver can be used in the position shown and gently levered down as indicate...

Page 31: ...0020107230_04 12 14 Glow worm MAINTENANCE 31 Diagram 12 7 14079 Diagram 12 8 13128 Diagram 12 11 14288 Diagram 12 10 14081 Diagram 12 9 14409 ...

Page 32: ...xceed beyond the service fill level see diagram 12 13 To clean the condense trap remove the sump and rinse with water Diagram 12 13 14089 SECURING NUTS 6 BURNER FAN CLAMPING BRACKET Diagram 12 12 14410 14397 12 8 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 wo...

Page 33: ... service isolation valve refer to section 13 4 Check that the heating system pressure indicates at least 1mb if not fill and vent the system as described in section 13 2 Check that all external controls are on Check the functional flow diagram 13 5 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 o...

Page 34: ...0020107230_04 12 14 Glow worm MAINTENANCE 34 13917 Diagram 13 4 ...

Page 35: ...0020107230_04 12 14 Glow worm MAINTENANCE 35 13012 Diagram 13 5 ...

Page 36: ...0020107230_04 12 14 Glow worm MAINTENANCE 36 Diagram 13 6 14029 FAULT CODES In all circumstances press the reset button to clear the fault If the fault persists consult the table below ...

Page 37: ...ENANCE 37 14029 Diagram 13 7 13131 STATE LISTS State list To access the state lists the button must be pressed for longer than 5 seconds until it begins to flash S and then a number to indicate the state The state numbers are given below ...

Page 38: ...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 parame...

Page 39: ... 5 Gas Valve Remove the three securing screws holding the gas valve to the fan see diagram 12 7 Remove the gas valve After re fitting check the combustion CO2 and adjust if necessary refer to section 12 1 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 14383 14 6 Flue H...

Page 40: ...xings nuts screws etc to fall into the open flue hood sump use a temporary cover whilst removing any parts 14 11 Condensate Trap For access refer to section 14 1 Remove securing screw see diagram 12 13 Disconnect the flexible condense drain pipe from the external plastic drain pipe beneath the boiler Carefully pull the condensate trap down and forward so as not to spill its contents The trap shoud...

Page 41: ...emove swivel flue 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...

Page 42: ...ng to the right to disengage the return pipe and tilting backwards to ease removal complete with sump Discard the heat exchanger and flanged elbows Remove the burner Remove the six flanged nuts and two studs that secure the burner note that the two studs also hold the fan clamping bracket see diagram 14 7 Taking great care not to damage the surface of the burner NOTE Replace the burner gasket and ...

Page 43: ...support the control box to avoid straining hinges as you push down and clip back into place 14 17 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 MPORTANT Support the control box whilst undoing the hinges Remove the hinge securing screws accessed f...

Page 44: ... Igniter unit H42773 3 0020020781 Heating flow return thermistor 2 H42792 4 0020020735 Gas valve 12hx 30hx H42724 4 0020059600 Gas valve 35hx H69002 5 0020020731 Spark Electrode H42720 6 0020020728 Burner 12hx 30hx H42718 6 0020059601 Burner 35hx H68999 7 0020023826 User interface H42784 8 0020023825 Main P C B H42783 15 Spare Parts ...

Page 45: ...ck straight bend using legs Keep load as close to body as possible Always use assistance if required Dispose of pack aging in a responsible manner Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance outside packaging Positioning of Appliance for Final Installation no obstructions This appliance is deemed to be a on...

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Page 49: ...tact Technical Helpline for advice CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE With boiler still set at minimum 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 CHECK CO AND COMBUSTION RATIO AT MAX RATE...

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Page 52: ...am Road Belper Derbyshire DE56 1JT www glow worm co uk These instructions or parts thereof are protected by copyright and may be reproduced or distributed only with the manufacturer s written consent 0020107230_04 12 14 ...

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