Glowworm cxi Owner's manual

Glow-worm,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
0020008566A.01.05
INSTALLERS INFORMATION
cxi & sxi
FLUE SYSTEM
Tel: [phone]
Fax: [phone]
These instructions are supplementary to the
literature supplied with the boiler and are for use
with :
Top Outlet Horizontal Concentric Flue Packs -
A2043600 and A2043400
Refer to diagram 1.
If you have been supplied with Standard
horizontal flue pack - Pt. No. 2000460360 or Pt.
No. A2037300, you will find the instructions for
the preparation and installation of these flues
within the literature supplied with your boiler.
12841
Diagram 1
TELESCOPIC
TERMINAL ASSEMBLY
SEALING
COLLAR
SEALING
COLLAR
SECURING
COLLAR
FLUE
ELBOW
GASKET
(fitted)
SEALING
TAPE (telescopic only)
Top Outlet Horizontal Concentric Flue Packs:
A2043600 Horizontal telescopic flue pack.
A2043400 Standard horizontal flue pack.
STANDARD
TERMINAL ASSEMBLY
SCREW x 1
SCREW x 2
SCREW x 2
SCREW x 4

2
0020008566A
2 Flue Location and Ventilation
2.1 Flue Options
This boiler is suitable for concentric Horizontal and Vertical
flues, elevated horizontal and vertical twin, all are fitted onto the
top of the boiler.
The Glow-worm Flue Options Guide, available on request or
through the web site, describes in detail the necessary
accessories.
These instructions describe the use of the standard and
telescopic horizontal flues.
The instructions for all other flues will be contained in those
packs.
TOP REAR FLUE - TELESCOPIC Diagram 2.1 Diagram 2.3
TOP REAR FLUE - STANDARD
2.2 Flue Length
The maximum permissable horizontal flue length is 10metres
plus the flue terminal, this can be achieved by use of the
accessories, however should additional 90oor 2 x 45oelbows
be used then the length MUST be reduced by 1metre.
When extension pipes are used the flue system must be
designed to have a continuous fall to the boiler of at least 2.5o
to allow condensate to run back into the boiler and out via the
drain.
The flue can be installed from inside the building, when access
to the outside wall face is not practicable.
The diagrams 2.1 to 2.4 describe the lengths achievable
without the use of extensions or elbows.
TOP SIDE FLUE - TELESCOPIC Diagram 2.2 Diagram 2.4
WALL THICKNESS
BOILER
MOUNTING WALL
OUTSIDE
WALL FACE
208 min. to 413 max.
87min 112
176
NOTE. If necessary, it is permitted to increase
this dimension to 600mm max.
L
FLUE
C
Max flue length 589mm
211239
20mm
min.
clearance
A
A
Max. distance from outside
wall face to min clearance.
LH - 330mm
RH - 358mm
Min. distance from outside
wall face to min clearance.
LH - 125mm
RH - 153mm
OUTSIDE
WALL FACE
87min
NOTE. If necessary, it is permitted to
increase this dimension to 600mm max.
INTERNAL
SURFACE
12837
12838
12839
12840
TOP SIDE FLUE - STANDARD
L
FLUE
C
Max flue length 849mm
211239
20mm
min.
clearance
A
A
Max. distance from outside
wall face to min clearance.
LH - 590mm
RH - 618mm
Min. distance from outside
wall face to min clearance.
LH/RH - 75mm
OUTSIDE
WALL FACE
87min
NOTE. If necessary, it is permitted to
increase this dimension to 600mm max.
INTERNAL
SURFACE
WALL THICKNESS
BOILER
MOUNTING WALL
OUTSIDE
WALL FACE
75 min. to 673 max.
87min 112
176
NOTE. If necessary, it is permitted to increase
this dimension to 600mm max.

30020008566A
2 Flue Location and Ventilation
Diagram 2.6
2.3 Terminal Position
The minimum acceptable siting dimensions for the terminal
from obstructions, other terminals and ventilation openings are
shown in diagram 2.5. For Ireland the minimum distances for
flue 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.
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.
It may be necessary to increase dimensions H & J if there is a
risk that the boiler products could stain any adjoining surface.
Increased siting flexibility can be achieved by using the Glow-
worm Plume Management Kit .
NOTE: If necessary it is permitted to increase the terminal
protrusion through the outside wall to greater than the minimum
dimension of 87mm but no more than 600mm, see diagram 1.1.
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.
H*and J*See diagram 2.5 . 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.
Plume Management Kit can be used to overcome many site
issues.
2.4 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 2.6.
A suitable guard is manufactured by: -
Tower Flue Components
Morley Rd.
Tonbridge
Kent
TN9 1RA.
Size: 280mm x 280mm x 270mm.
TERMINAL GUARD
Diagram 2.5
MINIMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS POSITION MM
HORIZONTAL FLUES
A DIRECTLY BELOW AN OPENING, AIR BRICK,
OPENING WINDOWS 300
B ABOVE AN OPENING, AIR BRICK,
OPENING WINDOWS 300
C HORIZONTALLY TO AN OPENING,
AIR BRICK, OPENING WINDOWS 300
D BELOW GUTTER, DRAIN/SOIL PIPE 25
E BELOW EAVES 25
F BELOW A BALCONY OR CAR PORT 25
G FROM VERTICAL DRAIN PIPES AND
SOIL PIPES 25
H FROM INTERNAL/EXTERNAL CORNERS 25
H TO A BOUNDARY ALONGSIDE THE
TERMINAL 300
I ABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
J FROM SURFACE OR A BOUNDARY
FACING THE TERMINAL 600
K FACING TERMINALS 1200
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 FLUE 300
*
*
12325

4
0020008566A
3 Installation Preparation
3.1 Wall Template
Take the wall template from the fixing jig pack and place in the
desired position on a flat wall, giving due consideration to boiler
clearances, see section 2, and the flue you are fitting.
IMPORTANT- If the template refers to type 'A' and 'B' flues,
please use only type 'B' references.
3.2 Flue Hole Cutting
The standard horizontal flue is designed with an internal fall
of 35mm/metre towards the boiler for disposal of condensate.
If the standard flue length alone is being used then the flue hole
of diameter 105mm can be cut in the position marked on the wall
template.
For standard side flues the horizontal flue centre line on the
wall template should be extended to the side wall, and the
vertical centre of the flue hole marked at 176mm from the back
wall.
For installations with external access, a 105mm diameter core
drill can be used.
For installations with internal access only a 125mm diameter
core drill should be used.
When using extension pipes with the horizontal rear flue, a core
drill size of 125mm should be used to allow the extension pieces
to slope at 35mm/metre (2.5°) towards the boiler.
For extended side flues, the flue hole centre should be
determined by extending the dashed inclined line on the template
to the side wall. This dashed line is drawn at 35mm/metre (2.5o)
rise from the boiler. Where this line reaches the side wall, a
horizontal line should be marked. The vertical centre line of the
flue should then be marked at 176mm from the back wall, see
diagram 3.2.
To allow for the flue 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 flue hole.
3.4 Fixing Jig and Hanging Bracket
Reposition the wall template over the flue hole and mark the
position of the fixing holes for the jig and the hanging bracket,
see diagram 3.3.
Drill the four fixing holes, 2 for the hanging bracket and 1 each
for the top hole of the fixing jig wall brackets and insert suitable
wall plugs.
If gas and/or water pipes are to be connected through the rear
wall, the holes must be drilled as marked on the wall template
prior to securing the fixing jig.
Secure the fixing jig wall brackets to the wall using suitable
screws.
NOTE: Due to the varied site conditions we do not supply fixings
and advise that the installer should supply those which are
suitable.
Locate the jig plate between the wall brackets and secure with
the No. 8 self tapping fixing screws supplied in the fittings pack.
130 130
191
16
Ø105
Ø125
2.5°2.5°
127
2.5°2.5°
Diagram 3.2
12075
WALL
TEMPLATE
EXTENDED SIDE FLUE
Ø 125
90°
176
2.5°Inclined
Extended flue length
Standard
flue length
Horizontal
HANGING
BRACKET
SCREW
(2 OFF)
SCREW
Diagram 3.3
12049
WALL PLUG
SCREW
WALL
TEMPLATE
FIXING JIG
PLATE
FIXING JIG
WALL BRACKETS
(2 OFF)
(Handed as shown)
WALL
PLUG

50020008566A
4 Flue Preparation Telescopic and Standard Flue
4.1 Flue Components
The components supplied in the Standard and Telescopic kit
are shown in diagram 1.
Additional flue accessories are available to suit your site
conditions, see diagram 4.1.
The Glow-worm Flue Options Guide, available on request or
through the web site, describes in detail the necessary
accessories.
Diagram 4.1
12842
45o Bend
2000460485
(2off)
90o Bend
2000460484
0.5m
EXTENSION
2000460481
1m
EXTENSION
2000460481
2m
EXTENSION
2000460481
VERTICAL
FLUE
ADAPTOR
2000460481

6
0020008566A
Diagram 4.3
Diagram 4.4
TOP SIDE FLUE - STANDARD
TOP REAR FLUE - STANDARD
Diagram 4.2
Diagram 4.5
TOP SIDE FLUE - TELESCOPIC
TOP REAR FLUE - TELESCOPIC
12658
12851
12850
12843
WALL THICKNESS 112
DRILL AND
SCREW
BOILER
MOUNTING WALL
OUTSIDE
WALL FACE
Y
DRILL AND
SCREW
COLLAR
WALL THICKNESS 112
DRILL AND
SCREW
BOILER
MOUNTING WALL
OUTSIDE
WALL FACE
Y
COLLAR
Y
INNER
PLASTIC
COLLAR
L
FLUE
OUTSIDE
WALL FACE C
OUTER
RUBBER
COLLAR
AIR
DUCT
FLUE
DUCT COLLAR
DRILL AND
SCREW
Y
INNER
PLASTIC
COLLAR
L
FLUE
OUTSIDE
WALL FACE C
OUTER
RUBBER
COLLAR
AIR
DUCT
FLUE
DUCT
COLLAR
DRILL AND
SCREW
4 Flue Preparation Telescopic and Standard Flue
4.2 Flue Length
Top Rear flue - Telescopic - with the flue elbow temporarily
fitted, measure the distance from the outside wall to the butt
joint, see diagram 4.2. If the measurement 'Y' exceeds 525mm
, then the appropriate length of extension pipe is required, if the
dimension is less than 320mm DO NOT cut the flue, it can
project to a maximum of 600mm, if this is not desirable then a
Standard flue MUST be used and cut to length.
Top Rear flue - Standard - with the flue elbow temporarily
fitted, measure the distance from the outside wall to the butt
joint, see diagram 4.3. If the measurement 'Y' exceeds 785mm
, then the appropriate length of extension pipe is required. The
minimum dimension is 187mm to suit a 75mm min wall thickness.
Top Side flue - Telescopic - with the flue elbow temporarily
fitted, measure the distance from the outside wall to the butt
joint, see diagram 4.4. If the measurement 'Y' exceeds 525mm,
then the appropriate length of extension pipe is required, if the
dimension is less than 320mm DO NOT cut the flue, it can
project to a maximum of 600mm, if this is not desirable then a
Standard flue MUST be used and cut to length.
Top Side flue - Standard - with the flue elbow temporarily
fitted, measure the distance from the outside wall to the butt
joint, see diagram 4.5. If the measurement 'Y' exceeds
785mm, then the appropriate length of extension pipe is
required. The minimum dimension for Lhd is 270 and Rhd 242
to suit a minimum wall thickness of 75mm.

70020008566A
4.2 (cont'd) Flue and Air Ducts
Telescopic:
The Telescopic Flue system MUST NOT be cut.
Adjust the flue to your required length "Y", mark the securing
hole position in the air duct. Drill two 3mm diameter holes at
these positions, take care not to pierce the inner flue duct.
Secure with screws provided and tape the joint, see diagram
4.6.
Standard:
Separate the flue duct from the terminal by twisting to release
the terminal catch, then pull out of the retaining seal, refer to
diagram 4.7.
The duct cutting lengths are shown in diagram 4.7.
The air duct should be cut at the opposite end to the terminal
fixing.
The terminal plastic duct MUST be cut at the opposite end to the
catch.
The plastic flue duct extensions MUST be cut at the opposite
end to seal.
The cut ducts must be de-burred and all filings and debris
removed.
NOTE: If you require to lubricate the seals to ease installation,
please do not use a mineral oil based grease, we would
recommend the use of water.
4.3 Flue Assembly
The flue assembly is a push fit design with securing collars.
Having adjusted the telescopic or cut the air and flue ducts as
described in section 4.2
Assemble the flue elbow to the air duct, ensuring the correct
alignment of the terminal. Fit the collar into position, mark
through two of the pre drilled holes in the collar. Remove collar
and drill two 3mm diameter holes in the elbow, take care not to
pierce the inner flue duct.
Insert the terminal flue duct, remembering to engage the catch
within the terminal, check for alignment.
Fit the rubber sealing collar behind the locating lugs on the flue
terminal, see diagram 1.
Push the flue assembly into the wall, externally or internally,
initially until the end of the assembly protrudes a short way from
the inside face of the wall. This will enable the internal trim ring(if
required) to be positioned and allow the flue duct to be drawn
back into the flue elbow after the boiler has been mounted.
4.4 Flue Attachment To Boiler
Secure the flue elbow in position on top of the boiler with four
torque headed screws supplied.
Draw the flue assembly from wall and engage the flue duct into
the elbow and butt fit the air duct, then fit the collar and secure
with screws provided, see diagram 4.8.
NOTE: If the air and flue ducts have been correctly cut to the
instructions given in section 4.2, the rubber sealing collar
should fit flush with the outside wall, check this.
Slide the internal trim ring back against the wall, securing in
place with a small amount of sealant if required.
4 Flue Preparation Telescopic and Standard Flue
Diagram 4.7
DUCT CUTTING LENGTHS
12847
Diagram 4.8
12846
TOP TELESCOPIC
AIR DUCT SECURING Diagram 4.6
AIR DUCT - TELESCOPIC
12852
AIR DUCT
FLUE DUCT
13mm
L
L + 11mm
L
TERMINAL
CATCH

8
0020008566A
FLUE ELBOW
COMBUSTION
ANALYSER
TEST POINT
FLUE DUCT
EXTENSION
Important Notes
To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced at
regular intervals. The frequency of servicing will depend upon
the particular installation and usage, but in general once a year
should be enough.
It is the Law that any servicing is carried out by a competent
person.
When replacing a part on this appliance, use only spare parts
that you can be assured conform to the safety and performance
specification that we require. Do not use reconditioned or copy
parts that have not been clearly authorised by Glow-worm.
5.1 General
Measurement of the products of combustion can be achieved
by connection of a probe to the combustion analyser test point,
see diagram 5.1.
IMPORTANT NOTE: Products of combustion will be discharged
when the cap is removed. It is important to replace the cap
immediately..
Testing Flue Gases: If any doubt exists that the flue products
are not exhausting correctly, investigate by use of a gas
analyser (FGA).
Diagram 5.1
12853
5 Servicing
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.