Flexicom cx combination boiler - installation and service manual

More documents

Recommendations

Info

13 ServicingIMPORTANT NOTES:1. To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced atregular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once ayear 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 SafetyExecutive.3. Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and thegas 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 andperformance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorisedby Glow-worm.5. If any electrical connections have been disconnected and after their connection, checks to the earth continuity, polarity,short circuit and resistance to earth must be repeated using a suitable multimeter, as described in section 14.6. After servicing, complete the relevant Service Interval Record section of the Benchmark Checklist located in the centrepages of this document.General InspectionPrior to, during servicing and after any maintenance orchanged parts, the following must be checked.● The integrity of the flue system and flue seals.● The integrity of the appliance combustion circuit andrelevant seals.● Electrical, gas and water connections.● System pressure.● the combustion performance, refer to the followingprocedure.● The operational gas inlet pressure and gas rates, refer tothe commissioning section paragraph 12.7.Correct any fault before continuing.COMPETENCY TO CARRY OUT THE CHECKOF COMBUSTION PERFORMANCENOTE: BS 6798: 2009 Specification for installation andmaintenance of gas-fired boilers of rated input not exceeding70kW net advises that:● The person carrying out a combustion measurement mustbe assessed as competent in the use of a flue gas analyserand the interpretation of the results.● The flue gas analyser used should be one meeting therequirements of BS7927 or BS-EN50379-3 and be calibratedin accordance with the analyser manufacturers’ requirements.● Competence can be demonstrated by satisfactorycompletion of the CPA1 ACS assessment, which coversthe use of electronic portable combustion gas analysers inaccordance with BS 7967, parts 1 to 4.● Ensure that the gas analyser is set to the correct fuelsetting.● Select the “ ”, constant central heating with DHWfunction by pressing °C the “Mode” button repeatedly, refer tobar °Ccommissioning section.Thebarboiler should fire automatically.NOTE: Safe combustion can only be verified by measuringCO/CO2 ratio. This must not exceed the value shown in thetable below.G20 BURNER % CO2MODEL CHECK SETTING CO/CO2ratio24cx 8.8 to 9.8 9.2 +0.3 0.004- 0.330cx 8.8 to 9.8 9.1 +0.3 0.004- 0.335cx 8.8 to 9.8 8.8 +0.3- 0.30.004COMBUSTION CHECK AND SETTING THE AIR/GAS RATIO VALVE● Remove the front casing panel, see diagram 13.2 and hingedown the control box. Taking care not to touch any internalcomponents, proceed as follows:● Connect the CO2 combustion analyser to the relevant testpoint, see diagram 13.1.1. Maximum Rate Check and AdjustmentDiagram 13.1NOTE: To verify the maximum gas rate CO2 setting theappliance must be checked at the maximum rate first. Pressthe “reset” button on the controls fascia, release andimmediately press and hold in the “+” button. Afterapproximately 5 seconds “Hi” will be displayed. Pressingthe mode button when “Hi” is selected will force the boilerto maximum rate, the display will flash between “Hi” and the“default display” this will indicate the boiler has been forced tomaximum. Wait until the CO2 value is stable and check thatthe value is within the range specified in table in the “check”column.If the combustion reading is not within the acceptable valuesAND the integrity of the complete flue system and combustioncircuit seals have been verified and the inlet gas pressure(and gas rate) have been verified, then, it will necessary toadjust the combustion rate of the appliance.NOTE: Adjustment is made by turning the gas valvethrottle an ⅛ of a turn, waiting 1 minute to allow theappliance to stabilise before checking or making furtheradjustments.1544542
13 Servicing● Rotate the “throttle”(anti-clockwise to increase), to therequired CO2, refer to diagram 13.4 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 defaultdisplay. Now proceed to check the minimum rate adjustment.All routine servicing requirements can be achieved by theremoval of the front panel, see diagram 13.2. Position thecontrol box into the service position, see diagram 13.3.Before commencing with a service or replacement of parts.The boiler should be isolated from the electrical and gassupplies.2. Minimum Rate Check and Adjustment● Now check the minimum gas rate CO2 setting: Pressand release the “reset” button on the controls fascia, thenimmediately press and hold in either of the “+” buttons. Afterapproximately 5 seconds “Hi” will be displayed. Pressing the“+” or “-” buttons will toggle between “Hi” and “Lo”. Press themode button when “Lo” is selected, this will force the boilerto minimum rate and the display will flash “Lo”, indicating theboiler is operating at minimum.● Wait until the CO2 value is stable and check that the valueis within the range specified in table in the “check” column.If adjustment is necessary, proceed as follows:NOTE: Adjustment of the CO2 at minimum rate is verycoarse and should not be adjusted more than an ⅛ ofa turn at a time. Wait 1 minute to allow the appliance tostabilise before checking or making further adjustments.● Gradually rotate the “offset adjustment” (anti-clockwise todecrease) to the required CO2, refer to diagram 13.4 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 defaultdisplay.3. Re-Check CO2 and check the CO/CO2combustion ratio.● Re-check the maximum and minimum CO2 values toensure that they are within the “setting” limits in the table thencheck the CO/CO2 combustion ratio does not exceed thevalue in the CO/CO2 column of the table. If the CO/CO2 ratioexceeds the value in the table, a complete servicing of theappliance will be necessary, refer to section 13.1.If the CO2 and the CO/CO2 ratio falls within the tolerancesquoted, exit the function press the “mode” and “+” buttonssimultaneously, this will reset the boiler to the default display.Remove the analyser probe and replace the cap on thesampling point, replace the controls fascia, inner and frontcasing panels.IMPORTANT: Remember to replace the sample point cap oncompletion of the test.GAS RATE CHECKCheck the gas rates as described in the commissioningsection.FRONTPANELSECURINGSCREWS13093Diagram 13.213554Diagram 13.312776COMPLETIONIf it is not possible to achieve the required results for eitherthe combustion or gas rates, it will be necessary to completea full service of the appliance and then repeat the combustioncheck procedure. If after servicing and adjustment of theappliance the combustion values are still unacceptableand after further remedial work has been carried out, theappliance must be disconnected until the CO/CO2 ratiois acceptable. Advice can be sought from the Glow-wormTechnical Helpline.13.1 ServicingNOTE: If the Combustion CO2, CO/CO2 ratio & Gas ratechecks did not require adjustment then it will not be necessaryto complete a full service.Diagram 13.443
Page 2 and 3: Guarantee RegistrationThank you for
Page 4 and 5: WARNINGSGas Leak or FaultTurn off t
Page 6 and 7: Boiler DesignThese boilers are desi
Page 8 and 9: 2 Boiler Dimensions and Hydraulic S
Page 10 and 11: 4 Flue Options and Terminal Clearan
Page 12 and 13: 5 Water System - Heating5.1 General
Page 14 and 15: 5 Water System - Domestic Hot Water
Page 16 and 17: 6 Installation Preparation6.1 Appli
Page 18 and 19: 8 Boiler Fixing8.1 Boiler HangingIM
Page 20 and 21: 9 Safety Discharge Valve and Conden
Page 22 and 23: 10 Telescopic Flue - Length, Prepar
Page 24: 10 Telescopic Flue - Length, Prepar
Page 29 and 30: 10 Direct Rear Flue - Length, Prepa
Page 31 and 32: 10 Vertical - Flue Length, Preparat
Page 33 and 34: 10 Twin Flue - Length, Preparation
Page 35 and 36: 10 Twin Flue - Length, Preparation
Page 37 and 38: 11 Electrical ConnectionWARNING: Th
Page 39 and 40: 12 Commissioning5. Open the two fil
Page 41: 12 CommissioningGas RateMake sure t
Page 45 and 46: 13 ServicingSECURINGSCREW (3)14079E
Page 47 and 48: 14 Fault Finding14.1 Preliminary fa
Page 49 and 50: 14 Fault FindingCENTRAL HEATING1301
Page 51 and 52: 14 Fault FindingState list - To acc
Page 53 and 54: 15 Replacement of Parts15.1 General
Page 55 and 56: 15 Replacement of Parts15.12 Silenc
Page 57 and 58: 15 Replacement of Parts15.23 Flow S
Page 59 and 60: 15 Replacement of Parts1439914414RE
Page 61 and 62: 16 Spare Parts16.1 Spare PartsWhen
Page 63 and 64: 18 Declaration of Conformity1450563

Flexicom cx combination boiler - installation and service manual

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?