Flexicom cx combination boiler - installation and service manual

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Boiler DesignThese boilers are designed for use as part of a sealed watercentral heating system with fully pumped circulation. Thepump, expansion vessel and associated safety devices are allfitted within the boiler. The hot water PRE HEAT temperaturefacility will improve the boilers hot water delivery response.The daily pump and 3 way valve exercise programmecombined with the built-in frost protection will help to maintainand protect the boiler.Range RatingThe boilers are fully modulating for central heating, it istherefore not necessary to range rate the boiler. However, ifdesired, it is possible to range rate the max. CH output in 1kWincrements, refer to section 12.Boiler DesignSafety DevicesCondensate DrainA plastic drain pipe must be fitted to allow discharge ofcondensate to a drain. Condensate should, if possible, bedischarged into the internal household draining system. Ifthis is not practical, discharge can be made externally intothe household drainage system or a purpose designed soakaway, see section 8 for more details.Pluming from flue terminalLike all condensing boilers this appliance will produce a plumeof condensation from the flue terminal in cool weather. This isdue to the high efficiency and hence low flue gas temperatureof the boiler. This is normal and not an indication of a fault.Electrical Supply FailureThe boiler will not work without an electrical supply.Normal operation of the boiler should resume when theelectrical supply is restored. Reset any external controls, toresume normal operation of the central heating. If the boilerdoes not resume normal operation press the reset button. Ifthe boiler does not resume normal operation after this callyour Installation/Servicing company or Glow-worm service.Overheating SafetyThe boiler software is designed to recognise the potentialfor an overheat lockout and will shutdown before thishappens. To restart the boiler, press the reset button on thecontrols fascia. If the boiler fails to resume normal operationand all external controls are calling for heat, then call yourInstallation/Servicing company or Glow-worm service.Safety Discharge ValveA safety discharge valve and discharge pipe are fitted to theboiler. This valve must not be interferred with, should therebe any discharge from the pipe, isolate the boiler electricalsupply and call your installer or Glow-worm’s own serviceorganisation using the telephone number on the inside frontcover of this booklet.Frost protectionThe appliance has a built in frost protection device thatprotects the boiler from freezing. With the gas and electricsupplies ON and irrespective of any room thermostat setting,the frost protection device will operate the pump when thetemperature of the boiler water falls below 8°C.A timer is used so that the temperature can be checkedperiodically. After 10 minutes the pump will be stopped if thetemperature is higher than 10°C or has already reached 35°C.The burner will activate if the boiler temperature does notreach 10°C after 30 minutes or at any time if the temperaturedrops to 5°C.The burner will switch off when the temperature reaches 35°C.Condensate Drain BlockageAs a safety feature the boiler will stop working if thecondensate drain becomes blocked. During freezingconditions an ice blockage in the condense drain, external tothe house would also activate the safety feature. Use warmcloths on the pipe to release an ice blockage.Once the blockage is removed the boiler should then restart.Servicing, Maintenance and Spare PartsServicing and MaintenanceTo ensure the continued efficient and safe operation of theboiler it is recommended that it is checked and serviced asnecessary at regular intervals. The frequency of servicing willdepend upon the particular installation conditions and usage.If this applaince is installed in a rented property there is a dutyof care imposed on the owner of the property by the currentissue of the Gas Safety (Installation and Use) Regulations,Section 35.Servicing/maintenance should be carried out by a competentperson approved at the time by the Health and SafetyExecutive in accordance with the rules in force in thecountries of destination.To obtain service, please call your installer or Glow-worm’sown service organisation using the telephone number on theinside front cover of this literature.Spare PartsRemember, when replacing a part on this appliance, useonly spare parts that you can be assured conform to thesafety and performance specification that we require. Do notuse reconditioned or copy parts that have not been clearlyauthorised by Glow-worm.If a part is required contact Glow-worm’s own serviceorganisation using the telephone number on the inside frontcover of this booklet.Please quote the name of the appliance, this infomation willbe on the name badge on the front of the appliance.If in doubt seek advice from the local gas company or Glowworm’sown service organisation using the telephone numberon the inside front cover of this booklet.6
1 Boiler SpecificationBOILER SPECIFICATION 24cx 30cx 35cxLift weight 36kg (79Ib) 36kg (79Ib) 36kg (79lb)14732Total weight (installed) 41kg (90Ib) 41kg (90Ib) 41kg (90lb)Gas connection Ø O.D. 15mm. copper 15mm. copper 15mm. copperHeating and return connection Ø O.D. 22mm. copper 22mm. copper 22mm. copperDomestic hot water connection Ø O.D. 15mm. copper 15mm. copper 15mm. copperCondensate connection Ø I.D. 21.5mm. plastic 21.5mm. plastic 21.5mm. plasticSafety valve discharge connection ØO.D. 15mm. copper 15mm. copper 15mm. copperHeating circuit safety valve (preset) 3 bar (43.5Ibf/in 2 ) 3 bar (43.5Ibf/in 2 ) 3 bar (43.5Ibf/in 2 )Heating system minimum pressure 0.7bar (10.1Ibf/in 2 ) 0.7bar (10.1Ibf/in 2 ) 0.7bar (10.1Ibf/in 2 )Maximum domestic hot water circuit 10bar (145Ibf/in 2 ) 10bar (145Ibf/in 2 ) 10bar (145Ibf/in 2 )Minimum working pressure to obtainmaximum domestic flow1.0bar (14.5lbf/in 2 ) 1.0bar (14.5lbf/in 2 ) 1.0bar (14.5lbf/in 2 )Minimum working pressure to obtaindomestic hot water0.2bar (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/minMin. flow rate around C.H. at 20° rise 776L/hr. 1032L/hr. 1204L/hrMaximum 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 3AElectrical rating 180W fused 3A 180W fused 3A 180W fused 3AEN437 IP clasification IPX4D IPX4D IPX4DInternal fuse rating on main PCB 2A 2A 2AGas supply (governed meter only) and Cat G20 natural gas G20 natural gas G20 natural gasGas Category I2H I 2H I 2HInlet gas working pressure 20mbar 20mbar 20mbarBurner % CO 2 case on 9.3 nominal 9.3 nominal 9.3 nominalBurner % CO 2 case off 9.3 nominal 9.3 nominal 9.3 nominalApproximate max. gas rateafter 10 mins. from coldApproximate min. gas rateafter 10 mins. from coldApproximate gas rateat part load.1.93 m 3 /h 2.59 m 3 /h 3.26 m 3 /h68.1 ft 3 /h 91.5 ft 3 /h 115 ft 3 /h0.99 m 3 /h 0.99 m 3 /h 0.99 m 3 /h35.1 ft 3 /h 35.1 ft 3 /h 35.1 ft 3 /hPLEASE REFER TO THE COMMISSIONING SECTIONFlue type C13, C33,C43,C53 C13, C33,C43,C53 C13, C33,C43,C53NOx Class 5 Class 5 Class 5Heat output condensing mode 18.8kW 24.9kW 31.0kWHeat input Nett Q = kW DHW max. 25.5 min. 9.4 DHW max. 30.8 min. 9.4 DHW max. 35.8 min. 9.4CH max. 18.3 min. 9.4 CH max. 24.5 min. 9.4 CH max. 30.8 min. 9.4Heat output P = kW DHW max. 25.1 min. 9.3 DHW max. 30.0 min. 9.3 DHW max. 35.0 min. 9.3CH max. 18.0 min. 9.3 CH max. 24.0 min. 9.3 CH max. 30.0 min. 9.3SEDBUK rating Band A 90.3% Band A 90.0% Band A 90.0%7
Page 2 and 3: Guarantee RegistrationThank you for
Page 4 and 5: WARNINGSGas Leak or FaultTurn off t
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 and 42: 12 CommissioningGas RateMake sure t
Page 43 and 44: 13 Servicing● Rotate the “throt
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
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