Glowworm Micron 80 Ff - Direct Heating Spares
Contents
1. 10 Replacement of Parts 10 11 Air Pressure Switch Part No 227053 diagram 10 6 Gain Access as Section 5 2 Remove the air pressure tubes and electrical connections from the switch release the screw and remove the switch When fitting the replacement make sure that the plastic tubes arefitted as shown in diagram 10 6 and the electrical connections as shown in diagram 9 5 10 12 Fan Part No 227035 diagram 10 7 Refer to Section 5 3 Remove the electrical connections and disconnect the air tubes NOTE Remove the electrical connections by pulling insulation boots only Remove the fan assembly securing screw at the front then withdraw the assembly The fan is secured to the flue hood by three screws The polarity of the electrical connections are not important 12276 REAR INSULATION SIDE INSULATION SIDE INSULATION RETAINING SCREW 7195 SECURING S SCREW 2 N S ey AIR JS PRESSURE m r7 A SWITCH i ELECTRICAL Ee AIR CONNECTIONS RED AIR TUBE Diagram 10 6 IMPORTANT REMOVE ELECTRICAL CONNECTIONS M BY GRIPPING THE BOOT ONLY CLEAR AIR REDAIRTUBE UBE ELECTRICAL CONNECTIONS S ES I f FAN SECURING SECURING SCREW FRONT INSULATION SCREW 3 Diagram 10 5 Diagram 10 7 27 2000225230C 11 Spare Parts 11 1 Part Identification 11 2 Ordering The part number2. 3 Water Systems 3 7 Open Vented Fully Pumped Heating and Domestic Hot Water The connections for the system MUST be as shown in diagrams 3 1 and 3 2 3 8 Inhibitor Attention is drawn to the current issue of BS5449 and BS7593 on the use of inhibitors in central heating systems When installing in an existing system take special care to drain the entire system including radiators then thoroughly cleaning outbefore installing the boiler whether or notadding an inhibitor 3 9 Sealed Water Systems Theinstallation should comply with the appropriate requirements of the current issue of BS4814 BS5449 BS6759 BS6798 and BS7074 Part 1 and 2 3 10 Safety Valve A safety valve must be fitted to a sealed water system It shall be preset nonadjustable with a lift pressure of 3bar incorporating seating of a resilient material a test device anda connection for drain The drain from the safety valve must be routed clear of any electrical fittings and positioned so that any discharge can be seen 3 11 Expansion Vessel Sealed Systems only A diaphragm type expansion vessel conforming to the current issue of BS4814 see also BS7074 Part 1 and 2 must be connected at a point close to the inlet side of the circulating pump unless laid down differently by the manufacturer The expansion vessel volume depends upon the total water system volume and the initial system design pressure For any system an accurate calculation
3. SCREWS 4 GASKET TOP TURRET 24 FLUE 7 DUCT EXTENSION Diagram 5 9 NOTE A SWITCH LIVE Ls SHOULD BE CONNECTED FROM AN EXTERNAL CONTROL IF NO EXTERNAL CONTROL IS AVAILABLE INSERT A LINK BETWEEN Lp amp Ls b bl b SUPPLY 4 ae 230V 50Hz ZI F BLOCK CONNECTOR 12385 br SECURING SCREW HINGE PIN GROMMET CONTROL BOX Diagram 5 10 T PIECE 7334 AIR VENT RETURN AIR VENT Diagram 5 11 2000225230C 16 6 Commissioning IMPORTANT NOTE The warning notice attached to the front of the boiler casing must only be removed by the user Please ensure the Benchmark logbook is completed and left with the user 6 1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798 Do not operate the boiler wthout water UNDER ALL CIRCUMSTANCES the case must be correctly fitted and sealed unless fault finding Make sure thatthe system has been thoroughly flushed out with cold water without the pump in place Refit the pump fill the system with water ensuring that all the air is properly vented from the system and pump 6 2 Sealed Water Systems Only Fill until the pressure gauge registers 2 7bar 40lbf in2 Clear any air locks and check for water soundness Check the operation of the safety valve by allowing the water pressure to rise until the valve opens The valve should op
4. low worm 2000225230C 04 05 Quality through design Instructions for Use Installation and Servicing Tobeleftwiththe user Micron SS SOFF G C No 41 047 51 Fanned Flue Boiler 7319 The code of practice for the installation commissioning amp servicing of gas central heating C Chenchmark This is a Cat L Appliance m 2H D Reference in these instructions to British Standards and Statutory Regulations Requirements apply only to the United Kingdom For Ireland the current edition of I S 813 Domestic Gas Installations must be used The instructions consist of three parts User Installation and Servicing Instructions 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 Guarantee Registration Thank you for installing a new Glow worm appliance in your home Glow worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive First Year Guarantee We recommend you complete and return your Guarantee Registration Card as soon as possible If this card is missing you can obtain a copy or record your registration by telephoning Glow worm s own service organisation on 01773 828100 Our Guarantee gives you peace of mind plus valuable protection against breakdown by cov
5. KEY TO TERMINAL BLOCK y 7 n 4 eA USE RESET BURNER bl b 3 15 LED LIT LED b MAINS SUPPLY 230V 50Hz br a BLOCK CONNECTOR LP L LS N M L X NOTE A switch live Ls should be connected from an external control If no external control is available insert a link between Lp amp Ls LP LIVE Permanent Ls LIVE Switched N NEUTRAL EARTH MAIN EARTH PUMP PL PUMP LIVE Pn PUMP NEUTRAL Diagram 9 5 2000225230C 24 10 Replacement of Parts IMPORTANT NOTES Replacement of parts must only be carried out by a competent person Before replacing any parts isolate the boiler from the electrical supply and turn the gas supply off at the gas service cock see diagram 6 2 Unless stated otherwise all parts are replaced in the reverse order to removal After replacing any parts always test for gas soundness and if necessary carryout functional check of controls 10 1 Access Gain Access as Section 5 2 10 2 Electrical Thermistor Part No 2000458914 Slacken control box securing screw and swing out the control box see diagram 5 9 Disconnectthe thermistor plug from the control board by slightly bending the retaining latch and removing the plug see diagram 10 1 Remove fan assembly see section 5 3 Remove the plastic R clips which retain all leads at the rear of boiler Carefully pull out
6. If this appliance is installed in a rented property in the UK 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 It is the law that any servicing is carried out by a competent person To obtain service please call your installer or Glow worm s own Service Organisation using the telephone number given on the front cover of these instructions Please be advised that the Benchmark logbook should be completed by the installation engineer on completion of commissioning and servicing All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your boiler Logbook You can check your installer is CORGI registered by calling CORGI direct on 01256 372300 Cleaning WARNING This appliance contains metal parts components and care should be taken when handling and cleaning with particular regard to edges Clean the casing occasionally by wiping it over with a damp cloth or dry polishing duster Do not use an abrasive cleaner To Turn the Boiler On Do not operate the boiler wthout water SEALED SYSTEMS only The pressure gauge should show at least 0 7bar anything less than this figure could indicate a leak and you MUST contact your installation servicing company ALL SYSTEMS Turn the electrical supply on to the boiler and check that all remote controls are calling f
7. Safety Temperature Limiter Ifthe safety Temperature Limiter operates on any other occasion than an electrical supply failure follow the procedure as in Electrical Supply Failure If the overheat operates again turn the appliance off and contact yourinstallation servicing company Protection Against Freezing If the boiler is to be out of use for any long period of time during severe weather conditions we recommend that the whole of the system including the boiler be drained off to avoid the risk of freezing up Make sure that if fitted the immersion heater in the cylinder is switched off Alternatively there is a built in frost protection which will cause the boiler when it is switched off at the control knob to operate in the event of the water temperature in the boiler dropping to 6 C or 7 C The boiler will switch off again when the temperature of the water in the boiler reaches about 15 C This will only protect the central heating system if the external controls are set so that the pump runs continuously that is they are calling for heat NOTE The frost protection will not operate if the electrical supply is turned off Maintenance To ensure the continued efficient 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 but in general once a year should be enough
8. Where the boiler is located in a restricted place see diagram 1 3 in Instructions for Use it may be necessary to remove the control knob to enable the control box to be fully swung out If the top flue outlet is to be utilised secure the top turret and gasket or flue spigot and gasket depending on desired flue orientation in position with the 2 taptite and 2 self tap screws provided see diagram 5 9 NOTE Ensure thatthe taptite and self tap screws are positioned as shown in diagram 5 8 to enable the air deflector to be fitted correctly If fixing to the back of the boiler i e spigot slide the flue into the spigot until it engages in the bayonet connection and then twist clockwise to lock see diagram 4 1 Make sure the fitting of the flue to the boiler is correct The fan assembly may also be removed or slid forward about halfway out of the boiler to ease access Disconnect the blue and purple electrical connections to the fan and the air pressure switch tube connections see diagram 5 5 NOTE Remove the electrical connections by pulling insulation boots only Remove the securing screw at the front see diagram 5 5 The fan assembly may now be slid forward 13 VIEW ON 2 COVER TOP CASE SECURING i7 i N sg N 7 ANS CONTROLS COVER Diagram 5 1 TUBING 4 RETURN g UNUN T TAILPIPE O RUBBER 3 FLOW lt TAIL PIPE HEATING HEATING RETURN FLOW 28mm Diagram 5 2 A PIPE
9. CD The mains cable outer insulation must not be cut back external to the cable clamp Make sure the cable is suitably secured When making connections make sure that the earth conductor is made of agreaterlength than the currentcarrying conductors so that if the cable is strained the earth conductor would be the SPIGOT last to become disconnected BLANKING 5 8 Pump Connection PLATE Route pump cable as mains see diagram 5 10 TS a SCREWS Connect to control box terminal block see diagram 9 5 4 TOP FLUE FIXING Diagram 5 6 FLUE DUCT RETAINING EXTENSION ja CLAMP 8 Lou N AN PRESS iB o a P PRESS FAN ELBOW NaN PRESS CLAMPING ELBOW CLASP SURFACE 6791 FAN ELBOW REAR JUBILEE JUBILEE area el CLIP TOP CLIP within casing CONNECTION Diagram 5 7 15 2000225230C 5 Boiler Installation After installation of the system preliminary electrical system checks as below should be carried out 1 Test insulation resistance to earth 2 Test earth continuity and short circuit of all cables 3 Test the polarity of the mains The installer is requested to advise and give guidance to the user of the controls scheme used with the boiler Fit the casing AIR 3 DEFLECTOR N SELF TAP SCREWS 5 2 HA v a e lt ME 4 Pu 9 TAPTITE Fo SCREWS 2 WING NUT Diagram 5 8 TOP TURRET FLUE OUTLET
10. THERMISTOR P C B CONNECTION Diagram 10 1 CE SECURING S GROMMET RETAINING L cer BRACKET URP bibe 7 THERMISTOR ELECTRICAL SAFETY CONNECTORS TEMPERATURE MITER Diagram 10 2 20002252300 10 Replacement of Parts 10 4 Control Board PCB Part No 2000227135 diagram 10 3 Remove casing see Section 5 2 Slacken control box securing screw see diagram 5 10 NOTE Toease access the control box may be pulled away from boiler by removing the hinge pins see diagram 5 10 Carefully pull the control knob and extension piece away from the PCB Carefully pull the board away from its supports Disconnect the electrical plugs by slightly bending back the retaining latches to allow withdrawal Disconnect the HT lead and spark earth lead When refitting refer to wiring diagram 9 5 Take care when replacing the control knob and extension by supporting the potentiometer on the P C B 10 5 Electrode Remove casing see Section 5 2 Remove combustion chamber front cover see diagram 10 5 Remove HT lead from electrode see diagram 8 5 Remove earth lead from electrode retaining bracket see diagram 8 5 Remove electrode bracket by undoing screw and withdrawing off locating pin see diagram 8 5 When refitting check spark gap see diagram 8 5 10 6 Multifunctional Control Part No 230509 diagram 10 4 Gain access as Section 5 2 Slacken control box securing screw and swing
11. gives full details of the requirements In IE the requirements given in the current edition of 1 S 813 Domestic Gas Installations and the current Building Regulations must be followed 3 1 Frost Protection There is a built in frost stat in this boiler See Protection Against Freezing in Instructions for Use Where other parts of the system are vulnerable this should also be considered as specified in the current issue of BS5422 3 2 Pump The pump with integral valves should be fitted in the heating flow pipework from the boiler it should be set to produce a temperature difference of 11 C 20 F between the flow and return with the boiler thermostat set at MAX which is about 82 C 180 F The pressure loss of the boiler at 30 6 litre minute giving 11 C temperature difference is 950mm head of water High resistance microbore systems may require a higher duty pump 3 3 Bypass A bypass is usually unnecessary on systems using a 3 port diverter valve since one port will remain in the open position at alltimes This allows satisfactory operation of the pump overrun However if thermostatic radiator valves are fitted to all radiators or two port valves are used a bypass is required The bypass connection must be at least 2 metres away from the boiler The flow through the boiler must not be allowed to fall such that there is a temperature difference greater than 20 C between the flow and return 3 4 Water Sys
12. should be inspected tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition of S 813 Domestic Gas Installations 2000225230C 14 MOUNTING S BRACKET MOUNTING BRACKET c SECURING SCREW NOTE PIPES REMOVED FOR CLARITY Diagram 5 4 CLEAR AIR RED AIF lt c PRESSURE ELECTRICAL PRESSURE J ype CONNECTIONS TUBE 7646 SECURING SCREW DEFLECTOR NOTE REMOVE ELECTRICAL CONNECTIONS BY GRIPPING THE BOOT ONLY Diagram 5 5 5 Boiler Installation 5 6 Control Box Access 5 9 Testing Slacken the control box securing screw see diagram 5 10 Checks to ensure electrical safety must be carried out by a Swing the box out on its hinge competent person 5 7 Electrical Connection 7150 WARNING This boiler must be earthed NOTE If an optional programmer is to be installed it should be EN e SCREWS fitted atthis stage see separate installation instructions supplied REAR FLUE with programmer FIXING Take care not to damage any internal wiring Using heat resistant 85 C cable of at least 0 75mm 24 0 2mm and of a suitable length thread through the grommet at the rear of the control box through the cable clamp and connect to appropriate terminals Tighten cable clamp screws see diagram 5 10 Standard colours are brown live L blue neutral N and green yellow earth
13. 19 Servicing 8 20 SERVICING Fault Finding 9 21 INSTRUCTIONS Replacement of Parts 10 25 Spare Parts 11 28 2000225230C 2 Instructions for Use Introduction Please read these instructions and follow them carefully for the safe and economical use of your boiler The Micron series are fanned flue boilers designed to provide central heating and indirect domestic hot water The boiler is fully automatic in operation having only one user control the temperature control WARNING It is important that the case is not disturbed or removed other than for servicing by a competent person Gas Leak or Fault Turnoffthe gas emergency control valve immediately Eliminate all sources of ignition i e smoking blowlamps hot air guns etc Do notoperate electrical lights or switches either on or off Open all doors and windows ventilate the area Electrical Supply Failure Failure of the electrical supply will cause the burner to go out Should this occur operation of the appliance will normally resume after the electrical supply is restored If the boiler does not relight after an electrical supply failure the overheat safety cutoff device may need resetting as indicated by illuminated reset light Open the controls cover and turn temperature control to 0 anticlockwise and then back to original position refer to diagram 9 1 NOTE If the boiler is switched OFF manually wait at least 30 seconds before switching on again
14. 3 15 Filling a Sealed Water System Provision for filling the system at low level must be made The installation should comply with the appropriate requirements of the current issue of BS 5449 3 16 Water Makeup Provision must be made for replacing water lost from the system A make up vessel mounted above the highest point of the system and connected through a non return valve to the system on the return side of either the hot water cylinder or heating system 6770 PUMPED RETURN 22mm VENT amp 15mm COLD FEED TO BE FITTED IN ACCORDANCE WITH BS 5449 k INDIRECT CYLINDER 7151 metre Min IF REQUIRED 27 metres BYPASS 22mm Max MIN WITH i LOCKSHIELD VALVE o ALTERNATIVE SYSTEM CONTROL VALVES HEATING SYSTEM FULLY PUMPED CIRCULATION SYSTEM DIAGRAMMATIC 22mm FOR COMBINED FEED amp VENT TO BE FITTED IN ACCORDANCE WITH BS 5449 7152 INDIRECT CYLINDER 27 metres BYPASS 22mm Max MIN WITH LOCKSHIELD VALVE DN HEATING SYSTEM o ALTERNATIVE SYSTEM CONTROL VALVES FULLY PUMPED CIRCULATION BYPASS DIAGRAMMATIC Diagram 3 2 20002252300 4 Flue and Appliance Preparation TOP OUTLET FLUE PACK STD EXTD FLUE LENGTH X plus 24 5mm RH 8 MAX 840mm extd 45mm 159 5mm LH flue length FLUE LENGTH S MAX 570mm std Easyfit MAX 840mm extd 415mm r EASYFIT MAX 570mm std Easyfit 144 5mm _ X plus 52 5mm
15. heating system on and off once or twice a day at whatever times you choose NOTE If the programmer is manually switched on then off when the boiler is cold the boiler may continue to operate for about 30 seconds before switching off 20002252300 Installation 1 General ELM ese TOP SIDE yd FLUE OPTION PUMPED RETURN 9 6 n L a PUMPED FLOW 7059 A zn WATER CONNECTIONS Q 22mm COPPER PIPE F j GAS CONNECTIONS RC in BSPT REAR FLUE Y OPTION ES P MODEL A B Cj D E F G H J K L M N P Q 80FF 298 75 122 370 146 556 67 5 85 115 128 126 156 100 157 40 92 108 STD EXD EASYFIT STD EXD EASYFIT All dimensions are given in millimetres Diagram 1 1 IMPORTANT NOTICE This boiler is for use on Natural Gas G20 as distributed in the United Kingdom and Ireland and cannot be used on any other gas This boiler must be installed by a competent person ONLY This boiler can be used on open vented or sealed water systems Domestic hot water must be provided by pumped circulation Wherever possible all materials appliances and components used shall comply with the requirements of applicable British Standards Where no British Standards exists materials and equipment should be fit for their purpose and of suitable quality a
16. it slide on be careful not to damage O ring Insert flue duct extension piece into top turret see diagram 5 7 NOTE Make sure thatthe flue duct extension piece is positioned so that the nibs are upper most see diagram 5 7 Locate the fan elbow with jubilee clip on the fan outlet do not tighten yet see diagram 5 7 Reconnect the blue and purple electrical connections to the fan the polarity of the connections is not important Reposition the fan assembly and draw down the flue duct extension piece onto the fan elbow see diagram 5 7 Fit the retaining clamp of the fan elbow bending the straps around the fan elbow raised clamping surfaces and fastening the claspthus securingitto the flue duct extension see diagram 5 7 It is important that the retaining clamp is fitted the correct way round so that the straps locate on to the fan elbow raised clamping surfaces Secure the fan elbow to the fan outlet with the Jubilee clip Continued Secure the fan assembly by replacing securing screw see diagram 5 5 Reconnect the air pressure switch tubes ensuring they are in the correct orientation as shown in diagram 10 7 5 4 Water Circulation System Complete the water connections to the boiler Fill vent and flush the system Check for any water leaks and put right 5 5 Gas Connection Make the gas connection to the Rc in gas service cock see diagram 6 2 The whole of the gas installation including the meter
17. 4 1 oo Ub KR OPTIONAL FLUE COLLAR Diagram 4 2 EASYFIT TOP z FLUE OUTLET 2 115mm MINIMUM HOLE TOP FLUE OUTLETS 115mm MINIMUM EASYFIT TOP FLUE OUTLET SIDE FLUE HOLE IXING POINT FLUE CENTRE LINE REARFLUE BOILER OUTLET UZ 1 FIXING POINT 115mm pod MINIMUM HOLE 77 BOILER CENTRE LINE Diagram 4 3 MOUNTING H BRACKET P Wee ir E Je PEN P 7 P WALL SECURING REUG SCREW o ND MOUNTING A j BRACKET o zt 2 FIXED TO BOILER Diagram 4 4 20002252300 4 Flue and Appliance Preparation Carefully drill though air duct pilot hole and secure with self tapping screw provided in fittings pack see diagram 4 1 Seal the joint with the tape provided If the flue system requires the addition of flue extension kits drill seal and secure them with the self tapping screw and tape provided The completed flue system must not exceed 3 metres see relevant part of diagram 4 1 NOTE Should any one of the flue sections require cutting to obtain desired flue system length cut the 1 metre extension kit at the end opposite the expanded end Make sure to cut square and remove any burrs If the boiler is notto be fitted for some time cover the hole in the wall NOTE If a horizontal flue extension is required it must be used in conjunction with the standard flue see diagram 4 1 IMPORTANT When using the standard flue kit either rear ou
18. H FROM SURFACE OR A BOUNDARY FACING THE TERMINAL 600 FACING TERMINALS 1200 J FROM OPENING DOOR WINDOW IN CAR PORT INTO DWELLING 1200 K VERTICAL FROM A TERMINAL 1500 L HORIZONTALLY FROM A TERMINAL 300 VERTICAL FLUES M FROM ADJACENT WALL TO FLUE 300 N FROM ANOTHER TERMINAL 600 P FROM ADJACENT OPENING WINDOW 1000 Q ABOVE ROOF LEVEL 300 Diagram 2 1 20002252300 2 Flue and Ventilation 2 3 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 aminimum of 50mm clearance from any part of the terminal and be central over the terminal see diagram 2 2 A suitable guard reference Type K3 can be obtained from Tower Flue Components Ltd Morley Road Tonbridge Kent TN9 1RA Ke Te o N d m E inn Renee INN I d Tn Hu T TH 4 Diagram 2 2 3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798 in Ireland refer also to the current edition of S 813 Domestic Gas Installations 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
19. ING e oo N POINT R bh n CLEAR AIR PRESSURE oe TUBES RED AIR AN PRESSURE 4 TUBE Diagram 8 1 N 8 BAFFLE Diagram 8 2 co re BURNER RETAINING PINS N SCREW BURNER RETAINING BAFFLE SUPPORT SCREWS Diagram 8 3 LOCATION PIN E LOCATION BURNER K PIN INJECTORS eNloeoo e650 0 8 oo Diagram 8 4 8 Servicing IMPORTANT Where the flue has a rear connection from back of casing see diagram 5 6 it is essential to make certain that the flue duct is fully located into the fan elbow until it can go no further enabling the flue duct to make a complete seal when secured 8 4 Injector Manifold With the burner removed the injector manifold can be inspected and cleaned as necessary see diagram 8 4 For cleaning do not use a wire or sharp instrument on the holes If any injectors are removed use a little suitable sealant on the external thread when refitting to make sure a gas tight seal is made 8 5 Operational Checks After completing a service and before fitting the case check condition of the case seal and renew if necessary Examine flue hood and terminal to make sure they are clean and clear of obstructions Refit all parts Light the boiler and carryout the functional checks as described ELECTRODE B JN EARTH 4 Zi LAL LEAD UE y EO IDZ yy A FA L RETAINING BRACKET 12274 Diagram 8 5 in Section 6 Testing F
20. If the terminal is fitted within 450mm below painted eaves or a painted gutter an aluminium shield 750mm long should be fitted immediately beneath the guttering or eaves 2 2 Flue Options There are various flue systems to choose from as follows Standard Top Outlet Flue Pack Pt No 230483 Easyfit Top Outlet Flue Pack Pt No 232057 Standard Rear Outlet Flue Pack Pt No 230482 Extended Top Outlet Flue Pack Pt No 230487 1 Metre Extension Kit Pt No 230484 A flue system up to 3 metres in length can be made by connecting 1 metre flue extension kits together Optional Wall Liner Kit No 900862 A Flue Bend Kit or Vertical Flue Kit up to 4 metres can be supplied see Glow worm s Flue Options Guide for configurations available 45 Flue Bend Pack Pt No 230485 90 Flue Bend Pack Pt No 230486 In Line Flue Adapter Kit Pt No 230488 Vertical Flue Kit No 458115 UNDER CAR PORT etc MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION MM HORIZONTAL FLUES A DIRECTLY BELOW ABOVE OR HORIZONTALLY TO AN OPENING AIR BRICK OPENING WINDOW AIR VENT OR ANY OTHER VENTILATION OPENING 300 B BELOW GUTTER DRAIN SOIL PIPE 25 C BELOW EAVES 25 D BELOW A BALCONY OR CAR PORT 25 E FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25 F FROM INTERNAL EXTERNAL CORNERS OR TO A BOUNDARY ALONGSIDE THE TERMINAL 25 G ABOVE ADJACENT GROUND OR BALCONY LEVEL 300
21. N RETURN puras AIRVENT amp NUT uence RAT gt TaN EEN Diagram 5 3 2000225230C 5 Boiler Installation Rear Flue fixing Fitthe fan elbow and secure with jubilee clip to the fan outlet do not tighten yet see diagram 5 7 Fit the retaining clamp of the fan elbow bending the straps aroundthe fan elbow raised clamping surfaces but do notfasten the clasp see diagram 5 7 It is important that the retaining clamp is fitted the correct way round so that the straps locate on to the fan elbow raised clamping surfaces Reconnectthe blue and purple electrical connections to the fan the polarity of the connections is not important Pull the flue duct into the fan elbow to engage IMPORTANT It is essential to make certain that the flue duct is fully located into the fan elbow until it can go no further Fasten the fan elbow retaining clamp clasp thus securing it see diagram 5 7 Secure the fan elbow to the fan outlet with the Jubilee clip Reposition fan assembly Top flue fixing Fit the two O rings from the loose items pack onto the flue duct extension there are recesses on the flue duct extension for locating them see diagram 5 7 Fit the air deflector in position using the rear left hand taptite screw and the one diametrically opposite which hold the top turret and secure with the wing nuts provided see diagram 5 8 NOTE Apply soap to seals on flue duct extension piece to help
22. ON Turn Gas ON Yes No Is there an LED sequence Replace PCB Yes o Refer to table Correct Operation Diagram 9 3 2000225230C 22 9 Fault Finding 10275 LED Fault Coding LED 1 LED 2 LED STATUS CONDITION RESET BURNER LIT Non Volatile Lockout Burner Lit PCB Failure Other Errors Simultaneous Phase Error Blocking Simultaneous Lighting Sequence Thermistor Alternating Blocking Error Software Error O O Q oO i O O Ignition Lockout O O O ici Simultaneous Lighting Sequence Fan APS E QQ Slow Flashing 2Hz i Fast Flashing 8Hz N N N o O H CUTOFF AIR b PRESSURE SWITCH SPARK ELECTRODE AIR PRESSURE SWITCH CONNECTIONS ho FUSE MAIN TERMINAL STRIP CONNECTIONS TYPE T3 15A 4 lt gt PRINTED CIRCUIT BOARD CONNECTIONS p Diagram 9 4 23 2000225230C 9 Fault Finding KEY BROWN BLUE GREEN YELLOW GREY BLACK PURPLE YELLOW RED ELECTRODE AIR i PRESSURE S SWITCH FAN GAS CONTROL VALVE SAFETY TEMPERATURE LIMITER THERMISTOR bk bk br br bk P C B CONTROL BOARD
23. RH l must include 50mm min SCREW side clearance amp TAPE X plus 187 5mm LH flue length STD EXTD ee Y plus 35mm flue length EASYFIT TOP OUTLET SIDE FLUE STD EXTD flue only TOP OUTLET REAR FLUE i us m flue leng Note Outer casing mounting brackets amp boiler details removed for clarity REAR OUTLET FLUE PACK 510mm MAX 15mm VIEW A SCREW amp TAPE VIEW A Eos Note Outer casing mounting brackets amp Y aplus orim 3 FLUE LENGTH boiler details removed for clarity EASYFIT STD EXTD TOP OUTLET FLUE PACK SCREW STD REAR OUTLET FLUE PACK amp 1 METRE EXTENSION KIT amp TAPE amp 1 METRE EXTENSION KIT 1 metre extension kits i ES 1 metre extension kits may be may be joined together VIEW B a joined together but the total but the total flue FOAM flue system must not system must not Total must not exceed 3m MAX SEAL exceed 2 metres ican 3 Metres NEW B s mm Total must not exceed 2m MAX M Msmm STD EXTD SIDE FLUE STD EXTD REAR FLUE X plus 24 5mm RH Y plus 35mm flue length 159 5mm LH flue length EASYFIT EASYFIT Y plus 63 5mm flue length X plus 52 5mm RH X plus 187 5mm LH flue length Note Outer casing mounting brackets amp boiler details removed for clarity M MAXIMUM DISTANCE FROM NOTE 19 MINIMUM MINIMUM MAXIMUM RA ue IF IT IS NECESSARY TO CUT THE DUCTS amp FLUE TO ACHIEVE THE FLUE LENGTH MAKE SURE BOILER MOUNTING FACE BOILER CA
24. S 813 BS5546 BS 5449 BS 7074 BS 7593 Manufacturer s instructions must not be taken as overriding statutory requirements NOTE For further information see the current issue of the Building Regulations approved document L1 in the UK and the references 1 GIL 59 2000 Central heating system specification CheSS and 2 GPG 302 2001 Controls for domestic central heating system and hot water BRECSU 1 2 Data See diagrams 1 1 1 2 and Table 1 All dimensions are given in millimetres The Seasonal Efficiency Domestic Boilers UK SEDBUK is 78 796 Thevalueis used inthe UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by B S 1 1 3 Range Rating This boiler is range rated and may be adjusted to suit individual system requirements referto diagram 1 2 for data label position ratings and settings 1 General 1 4 Gas Supply The gas installation shall be in accordance with the relevant standards In GB this is BS6891 In IE this is the current edition of 1 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 soundness using the pressure drop method purge in accordance with the above standard a 458685 Glow worm PE ay fas fo E HEP
25. SING TO THICKNESS LENGTH LENGTH THAT THE OVERLAPS ARE AS FOLLOWS TO EXTERNAL WALL FACE EXTERNAL WALL FACE THE OVERLAP FOR AIR DUCT 25mm TOP STD THE OVERLAP FOR FLUE DUCT 50mm EASYFIT REAR 111 SIDE R H 102 SIDE L H 237 TOP EXTD REAR 111 SIDE R H 102 SIDE L H 237 REAR STD REAR Diagram 4 1 2000225230C 10 4 Flue and Appliance Preparation NOTE Make sure thatthe ductings do not slope down towards the boiler 4 1 Flue Position and Length Determine flue application length and terminal position before starting Refer to diagram 4 1 If you are using a Flue Bend or a Vertical Flue Kit please follow the instructions supplied with the kit To make a neat finish to the flue outlet a flue collar kit part No 900850 with instructions is available see diagram 4 2 4 2 Flue Preparation All flue assemblies are designed for internal installation given that there is sufficient clearances opposite to the flue for the installation of the flue If there is insufficient clearance the flue can be installed from outside For a wall thickness up to 300mm and provided that there is sufficient space an optional wall liner kit is available for the flue to be installed from the inside For a wall thickness of over 300mm the external flue hole will need to be made good from the outside This applies also if you use the flue kit without the optional wall liner kit irrespective of w
26. WORTH HEATING LTD BELPER DERBYS DE56 1JT MICRON 80FF 230V 50Hz 81W Fused at 3A TYPE C12 C32 For use on G20 gas only E Supply pressure 20 mbar NOx Class 2 PMS 3 0 bar This boiler is intended exclusively GC No 41 047 51 9445 to be installed on a gas supply with a governed meter CE 0086 G B IE INJECTOR 1 15mm 205763 86 AT 565 1 I 1 I I 1 1 RANGE RATING I 1 I I 1 HEAT INPUT kW NETT Q Btu h 70000 HOT BURNER mbar 9 8 PRESSURE inwg 3 9 Position against setting SERIAL No M J PMS 3 0 bar is Maximum water side operating pressure The appliance flue type is a C and C This refers to a concentric flue where the fan is downstream of the heat exchanger The C is a horizontal flue termination and the C is a vertical flue termination Oo D N Diagram 1 2 TABLE 1 TOTAL DRY WEIGHT 49 2 kg Including Terminal LIFT WEIGHT 40 3 kg WATER CONTENT 3 35 litre 0 74 gallon GAS CONNECTION Rc in 81W ELECTRICITY RATING Internal fuse Type T3 15A WATER CONNECTION 2x22mm copper pipes from back of case ELECTRICITY SUPPLY 230V 50Hz fused 3A DATA LABEL Top left of inside of case 1 5 Electrical Supply WARNING This boiler must be earthed All system components shall be of an approved type and shall be connected in accordance with the current issu
27. all thickness 4 3 Rear and Side Flue Application Select the boiler location and flue application with due regard to the terminal position see diagram 2 1 Take the template from the boiler pack and temporarily position it on the wall making sure that the minimum clearances are maintained see diagram 4 3 Mark the centre line position of the flue Top or Rear as diagram 4 3 For aside flue extend centre line of Top to L H or R H corner Mark the position of the centre of the flue and boiler as diagram 4 3 4 4 Flue Hole Cutting Having marked out the flue centre cut a hole for the flue using preferably a 115mm minimum core drill NOTE If required an optional wall liner kit part no 900862 is available complete with instructions 4 5 Wall Mounting Bracket Reposition the template making sure of dimensional alignment with the flue hole Mark the boiler fixing points and mounting bracket positions see diagram 4 4 NOTE The lower mounting bracket is fixed to the boiler Drill the holes and insert wall plugs Secure the top mounting bracket to the wall with two No 12x2in wood screws one on each side of the bracket see diagram 4 4 Alternative fixing positions are provided inthe bracket if required 4 6 Flue Duct Extend the telescopic flue to the required length making sure that the minimum overlap is no less than 25mm and thatthe flue terminal projects 15mm minimum beyond wall face see diagram
28. d 1 14 Timber Frame Building 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 local gas undertaking or Glow worm 1 15 Anti theft Kits Anti theft kits are available for these appliances contact Glow worm for further information 2 Flue and Ventilation The flue must be installed in accordance with the rules in force in the countries of destination 2 1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions other terminals and ventilation openings are shown in diagram 2 1 For Ireland the minimum distances for flue terminal positioning must be those detailed in l S 813 Domestic Gas Installations The terminal must be exposed to the external air the position allowing free passage of air across it at all times Car ports or similar extensions of a roof only or a roof and one wall require special consideration with respectto any openings doors vents or windows under the roof Care is required to protect the roof if it is made of plastic sheeting If the car port consists of a roof and two or more walls seek advice from the local gas company before installing the boiler If the terminal is fitted within 600mm below plastic guttering or painted soffit an aluminium shield 1500mm long should be fitted immediately beneath the guttering or eaves
29. d be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules The boiler must be mounted on a flat wall which is sufficiently robust to take its total weight The boiler may be fitted to a wall made of combustible material 1 11 Boiler Clearances Refer to diagram 1 3 This boiler must be positioned so that at least the minimum operational and servicing clearances are provided Additional clearances may be required for installation If fixtures are positioned next to the boiler ensure access is provided for pipework installation At least a minimum clearance of 320mm from a permanently fixed surface must be left in front of the boiler for servicing see diagram 1 3 1 12 Room Ventilation The boiler is room sealed and does not require the room or space containing it to have permanent air vents 2000225230C 1 13 Boilers in a Compartment Where the installation ofthe boiler will be in an unusual position the current issue of BS6798 gives detailed guidance on these requirements An existing cupboard or compartment modified for the purpose may be used providing minimum clearances are maintained Details of essential requirements for cupboard or compartment design are given in the current issue of BS6798 The doorway opening should be of sufficient size to allow for easy removal of the boiler Where the boiler is fitted in a cupboard or compartment permanent ventilation is not require
30. e of BS7671 and any applicable local regulations External wiring must be correctly earthed polarised and in accordance with the relevant standards In GB this is BS6891 In IE this is the current edition of 1 S 813 Domestic Gas Installations Connection of the boiler and system controls to the mains supply must be through a common isolator and must be fused 3A maximum This method of connection must be by a fused double pole isolating switch with a minimum contact separation of 3mm on both poles The switch should be readily accessible and preferably adjacent to the appliance It should supply the appliance only and be easily identifiable as so doing Alternatively an unswitched shuttered socket outlet and 3A fused 3 pin plug both to the current issue of BS1363 may be used provided that 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 75mm 24 0 20mm 1 6 Contents of Packaging The boiler is delivered in two or more packs depending on flue System refer to diagram 4 1 for contents 1 7 Water System This boiler may be fitted to an open vented or a sealed water system 1 8 Draining Tap System A draining tap must be provided at the lowest points of the system which will allow the entire system and hot water cylinder to be drained Draining taps should be to the current issue of BS2879 Boiler A draining point is fitted at the b
31. en within 0 3bar 4 3lbf in of the pre set pressure Where this is not possible conduct a manual check and test NOTE Fit a suitable discharge pipe to the safety valve and route itto outside the building so that any discharge can be seen but will not cause injury to persons damage to property or any electrical installation Release cold water to initial system design pressure The set pointer on the pressure gauge should be setto coincide with the indicating pointer 6 3 Initial Lighting and Testing CAUTION This work must be carried out by a competent person in accordance with the current issue of BS6798 Make sure that boiler case is fitted securely Make sure that all naked lights and cigarettes are out Open the control cover refer to the Instructions for Use and identify the controls see diagram 9 1 Remove fascia see diagram 6 1 Check that the boiler is isolated from the electrical supply Make sure that the temperature control is turned to the 0 Off position see diagram 9 1 Undo the screw which holds the control box refer to diagram 5 10 Swing open control box Turn the gas service cock On see diagram 6 2 A 14mm spanner may be required for this Purge in accordance with the current issue of BS6891 Replace control box Turn on the electrical supply WARNING The multifunctional control and fan operate on mains voltage terminals will become live If programmer control fitted make s
32. ering the cost of ff All replacement parts REGISTER YOUR GLOW WORM APPLIANCE A All labour charges FOR 1ST YEAR GUARANTEE PROTECTION A All call out charges CALL 0800 073 2142 Glow worm Glow worm Tel 01773 828100 Nottingham Road Belper Derbyshire DE56 1JT C E Fax 01773 828070 General Sales enquiries Tel 01773 824141 Fax 01773 820569 www glow worm co uk Important Information Testing and Certification This boiler is tested and certificated to EN483 for safety and performance It is therefore important that no alteration is made to the boiler without permission in writing from Glow worm Any alteration not approved by Glow worm could invalidate the certification boiler warranty and may also infringe the current issue of the Statutory Requirements CE Mark This boiler meets the requirements of Statutory Instrument No 3083 The boiler Efficiency Regulations and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purposes of Regulation 5 certified by Notified body 0086 Product production certified by Notified body 0086 The CE mark on this appliance shows compliance with 1 Directive 90 396 EEC on the approximation of the Laws of the Member States relating to appliances burning gaseous fuels 2 Directive 73 23 EEC on the harmonization of t
33. he Laws of the Member States relating to the 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 INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER Under Section 6 of The Health and Safety at Work Act 1974 we are required to provide information on substances hazardous to health Insulation pads and Glass yarn These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow normal good hygiene and wash your hands before eating drinking or going to the lavatory If you do suffer irritation of the eyes or severe irritation to the skin seek medical attention 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 specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Glow worm CONTENTS DESCRIPTION SECTION PAGE No Introduction 3 INSTRUCTIONS Lighting the Boiler 3 FOR USE General Data 1 4 Flue and Ventilation 2 7 INS TACERTION Water Systems 3 8 INSTRUCTIONS Flue and Appliance Preparation 4 10 Boiler Installation 5 13 Commissioning 6 17 Instructions to the User 7
34. ids will open andthe burner will light This is shown by the Burner Lit LED on the control panel lighting up The burner will stay alight until switched off either by the temperature control or remote system control At this point the fan will overrun by 5 seconds To make sure that the flame supervision device is working correctly the following should be done With the burner alight turn the gas service cock OFF see diagram 6 2 After a short period the burner will go out but the fan will overrun for 5 seconds The correct working ofthe flame supervision device is shown by the Burner Lit LED going out and the lighting sequence starting up as follows 1 Fan starts Spark ignition operates for 10 seconds Fan will overrun for 5 seconds The fan will start again a BR C0 Nm After 10 seconds the spark ignition operates this continues for a further 10 seconds 6 Fan will overrun for 5 seconds This sequence is repeated ONCE more and the boiler will shut down The following illumination will happen with the LED on the front of the control panel Reset permanently ON and Burner Lit flashing fast 8 Hz If the above lighting sequence fails refer to section 9 Fault Finding To continue turn the gas service cock On see diagram 6 2 To restart the lighting sequence turn the temperature control knob to O then fully clockwise to Max During Normal Operation when the boiler switches Off
35. ign control cover with casing When the temperature control is turned to the O position by hand wait at least 30 seconds before turning On again There may be an initial smell given off from the boiler when new this is quite normal and it will disappear after a short period of time 6 6 Testing All Water Systems Allow the system to reach maximum working temperature and examine for water leaks There should be no undue noise in the system The boiler should then be turned off and the system drained off as rapidly as possible whilst still hot Refill system 6 7 Open Vented System Ensure there is no pumping over of water or entry of air at the open vent above the feed and expansion cistern 6 8 Adjustment Fully Pumped Open Vented and Sealed Water Systems When commissioning the system the boiler should first be fired on full service that is central heating and domestic hot water Adjust the pump to the system design setting then balance the system making adjustments as necessary 6 9 Thermostatic Radiator Valves If thermostatic radiator valves are fitted care must be taken to ensure that there is an adequate flow rate through the boiler when they close refer to the current issue of BS7478 for guidance If fitted to all radiators ensure a bypass is fitted and adjust to achieve a temperature difference no greater than 20 C between flow and return with the thermostatic valves closed 6 10 Completion Adju
36. lue inside and outside after installation of the boiler IMPORTANT If the wall liner kitis used the self adhesive foam seal included must be used in place of the one supplied with the flue pack see diagram 4 5 for position of self adhesive seal 4 10 Flue Positioning Push the flue assembly into the hole such thatit is within the wall and does not stick out into the room Do not push the flue assembly too far into the hole as it has to be pulled back into the boiler and secured 20002252300 12 WITH WALL LINER KIT ONLY WALL THICKNESS FOAM SEAL UP TO 300mm 7331 FOAM SEAL WALL THICKNESS OVER 300mm IS Diagram 4 5 STANDARD 510mm REAR AND STANDARD 570mm TOP FLUE ONLY EASYFIT 570mm or less 7323 FLUE TERMINAL CLAMPING BRACKET LOCKING SCREW CLAMPING BRACKET NIB 7332 TERMINAL RESTRICTOR SHOWN FITTED Diagram 4 6 5 Boiler Installation 5 1 Unpacking Open the carton check the items supplied against the boiler pack contents list on the carton flap 5 2 Boiler Preparation With the boiler still in the bottom tray remove the casing front cover Open the controls cover first then by undoing the two screws at the bottom and the one at the top lift the front cover off see diagram 5 1 Place front cover in a safe place on one side until required Remove boiler From the fittings pack slide a tubing nut and washer on to the return and flow
37. lue Gases If any doubt exists that the flue products are not exhausting correctly investigate by use of a gas analyser FGA 9 Fault Finding 9 1 Electrical IMPORTANT On completion of the Service Fault Finding task which has required the breaking and remaking of the electrical connections the earth continuity polarity short circuit and resistance to earth checks must be repeated using a suitable multimeter Refer to Boiler Fault Finding see diagram 9 3 Pump Overrun Fault Finding see diagram 9 2 Fault Finding Wiring Diagram see diagram 9 4 Pictorial Wiring Diagram see diagram 9 5 9 2 Electrical Supply Failure Failure of the electrical supply will cause the burner to go out Operation will normally resume onthe restoration ofthe electrical supply Ifthe burner does not relight after an electrical supply failure the overheat device may need resetting Open the control cover see diagram 9 1 and if the RESET neon is lit turn temperature control on the front of the control box to 0 and then back again see diagram 9 1 If the safety temperature limiter operates at any other time do as above the burner should relight If the fault persists refer to fault finding chart CONTROL KNOB 6771 Reset Burner On O O 7166 CONTROLS COVER Diagram 9 1 NO Does the pump run when SL is applied Pump Overrun Operation The PCB has a timed pump overrun facility The pump sho
38. nd workmanship Sealed Components Under no circumstances must the User interfere with or adjust sealed parts Sheet Metal Parts WARNING When installing or servicing this boiler care should betaken when handling sheet metal parts to avoid any possibility of personal injury 1 1 Statutory Requirements In GB the installation of the boiler must be carried out by a competent person 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 Fittings Regulations or Water byelaws in Scotland The Health and Safety at Work Act Control of Substances Hazardous to Health COSHH The Current I E E Wiring Regulations Where no specific instructions are given reference should be 2000225230C made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent person and installed in accordance with the current edition of 5 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation In 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 In IE I
39. nd the Benchmark logbook with the user 19 20002252300 8 Servicing REMEMBER When replacing apart 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 Products of Combustion Check NOTE To obtain aproducts of combustion reading remove the cap from the sampling point located on top of the inner casing see diagram 8 1 Connect the analyser tube onto the nipple Switch on the electrical supply and gas supply then operate the boiler On completion of the test switch off the electrical supply and the gas supply remove analyser tube and replace sampling point cap Servicing Before servicing turn off the gas and isolate the electrical supply to the boiler After completing a service always test for gas soundness make electrical checks and carry out functional check on controls Unless stated otherwise all parts are replaced in the reverse order to removal 8 1 Access Remove the boiler case see diagram 5 1 and Section 5 2 8 2 Burner Remove front combustion chamber cover which is secured by two screws see diagram 10 5 Remove electrode bracket by undoing screw and withdrawing off locating pin see diagram 8 5 The HT lead and earth lead still connected will allow electrode to hang down at the front of the appliance Remove cont
40. of the vessel size is given in the current issue of BS7074 Part 1 Example For an initial system design pressure of 0 7bar the minimum total vessel volume required is 0 063xTotal System volume NOTE Ahigher initial design pressure requires alarger volume expansion vessel Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1 for IE refer to the current edition of 1 S 813 Domestic Gas Installations The charge pressure must not be less than the static head of the system that is the height of the highest point of the system above the expansion vessel The water content of the boiler is given in Data Table 1 3 12 Pressure Gauge Sealed Systems only A pressure gauge with a set pointer and covering at least the range of 0 to 4bar 0 to 60lb in shall be permanently fitted to the system in a position where it can be seen when filling the system 3 13 Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE The domestic hot water cylinder must be of the indirect coil type It must be suitable for working at a gauge pressure of 0 35bar above the safety valve setting 3 14 Domestic Hot Water System Unvented Where a storage system will not have a vent to atmosphere the installation must comply with Building Regulations and local Water Company Bye laws see also the current issue of BS6700 If fitting into an existing system the local authority must also be advised
41. on the diagram location will help to identify the When ordering any spare parts please quote the number and part description from the list together with the model name and serial number If ordering from the local gas undertaking also quote the GC number of the appliance Description Location GC Part No 2000801 136 Multifunctional control Diagram 10 4 E24965 227035 Fan Diagram 10 7 E24976 227053 Air pressure switch Diagram 10 6 E24973 2000458914 Electrical thermistor Diagram 10 1 amp 10 2 Ma ie 2000802541 Spark electrode Diagram 8 5 E24957 204697 Control knob Diagram 10 3 E24870 205763 Injector Diagram 8 4 SEP 227098 Fuse Diagram 10 3 Bree wrt 2000227135 Control board Diagram 10 3 are 227038 Safety temperature limiter Diagram 10 2 E24897 O AN OAK WN 112525 Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions 2000225230C 28
42. or heat Open the controls cover see diagram 9 1 Check also that the programmer if fitted is in the ON mode Turn the control knob clockwise to any position between O and MAX The maximum temperature setting is approx 82 C 180 F see diagram 9 1 The boiler lighting operation is now automatic as follows The fan will operate for a short period prior to the start of the ignition sparks The gas valve solenoids will open and the burner will light This is shown by the Burner Lit LED on the control panel lighting up The burner will remain alight until switched off by the control thermostat any remote control or the programmer NOTE If the boiler is switched OFF by hand wait at least 30 seconds before switching on again When the boiler switches off the boiler will go out The automatic lighting sequence will operate again when heat is required Shut the controls cover It should be noted that this is a fan flue appliance and fan operation may be heard To Turn the Boiler Off For short periods turn the control knob anti clockwise to O Off To relight turn the control knob to any position between O and MAX For longer periods turn the control knob fully anti clockwise to 0 Off and switch off the electrical supply to the boiler To relight follow the lighting sequence given above Optional Programmer A programmer is available which will automatically switch your central
43. ottom right hand side of the heat exchanger When draining is required cover the controls to avoid water damage If required remove the combustion chamber front cover to improve access 1 9 Safety Valve A safety valve need not be fitted to an open vented system 2000225230C 1 General 10mm FROM A NON PERMANENT 320mm FROM A PERMANENT 190mm with Easyfit top flue fitted 160mm with standard extended top flue fitted 20mm without top flue fitted below to permit access to air vent WORKTOPS AND INFLAMMABLE MATERIALS Increased top clearance is required if flow pipe enters from MINIMUM CLEARANCES FROM WALLS CEILING FLOOR CUPBOARD EE 6mm 2mm FRONT VIEW 50mm 160mm WITH TOP FLUE FITTED 20mm WITHOUT TOP FLUE FITTED Diagram 1 3 1 10 Location This boiler is not suitable for outdoor installation The boiler may be installed in any room although particular attention is drawn to the requirements of BS7671 with respect to the installation of a boiler in a room containing a bath or shower Any electrical switch should be so positioned that it cannot be touched by a person using the bath or shower The electrical provisions of the Building Standards Scotland Regulations apply to such installations in Scotland 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 shoul
44. out the control box see diagram 5 10 Disconnect the electrical plug Disconnect from the gas cock by removing the four extended screws from the flanged connection at the right hand side Supportthe multifunctional control disconnectfrom the manifold by removing the tubing nut from the left hand side Remove and discard the original O ring from the flanged connection and fit the new O ring supplied into recess before fitting the replacement multifunctional control After assembly testfor gas soundness and purge in accordance with the current issue of BS6891 or in IE the current edition of S 813 Domestic Gas Installations 10 7 Solenoid diagram 10 4 Remove the electrical plug from the multifunctional control Remove the securing screw and then the solenoid assembly 10 8 Burner Remove the burner as Section 8 2 10 9 Injectors Part No 205763 Remove the burner as Section 8 2 Remove the injectors as Section 8 4 2000225230C 26 10 10 Insulation diagram 10 5 Combustion Chamber Front Gain Access as Section 5 2 Remove the combustion chamber front then the insulation Sides Slide the insulation out Rear With the side insulation removed the rear insulation can be removed and replaced P C B FUSE 12006 P C B EXTENSION SUPPORT PIECE CONTROL KNOB Diagram 10 3 co SOLENOID EXTENDED SECURING SECURING SCREW SCREWS 4 SOLENOIDS ELECTRICAL PLUG Diagram 10 4
45. rol box retaining screw and swing control box out see diagram 5 10 Remove burner retaining screws located under boiler casing see diagram 8 3 Pull out burner together with the baffle support see diagram 8 3 To remove baffle support from burner slide off retaining pins see diagram 8 3 Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly making sure that all the burner ports are clear and unobstructed On refitting and after cleaning the heat exchanger make sure the burner is fitted correctly that is located on the injector manifold pins and horizontal see diagram 8 4 NOTE It is advisable while servicing the burner to check the combustion insulation and replace if damaged see Section 10 10 8 3 Cleaning Heat Exchanger Flueways Disconnect the air pressure switch tube connections red from fan both clear tubes from test nipple see diagram 8 1 Remove the blue and purple electrical connections from the fan See diagram 5 5 Remove the fan assembly complete with the flue elbow see diagram 5 5 and Section 5 3 Place a sheet of paper in the base of the combustion chamber and over the injectors to prevent particles entering Remove the baffles see diagram 8 2 Clean the heat exchanger flueways with a suitable stiff brush Remove the paper together with any debris 2000225230C 20 SAMPL
46. st the boiler temperature control and any system controls to their required settings In addition it is necessary to complete the Benchmark logbook For IE itis 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 Testing Flue Gases If any doubt exists that the flue products are not exhausting correctly investigate by use of a gas analyser FGA 7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the boiler heating system and domestic hot water system Advise the user thatto ensure the continued efficient and safe operation of the boiler itis 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 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 servicing is carried out by a competent person Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system being out of use during frost and freezing conditions Reminder Leave these instructions a
47. tail pipes which are supplied with the boiler see diagram 5 2 Connectthe return and flow tail pipes to the boiler see diagram 5 2 Fit suitable compression fittings to the tail pipes For pipework entering the boiler from below an optional flow and return pipe incorporating an air vent is available kit No 2000458585 see diagram 5 3 NOTE If the installer wishes to adapt the standard pipework he may do so but must incorporate an air vent at the highest point on the flow pipe and the highest point of the return pipe see diagram 5 11 5 3 Mounting the Boiler Ensure to fit the blanking plate and gasket on the boiler flue outlet not being utilised see diagram 5 6 If the rear flue outlet is to be utilised for the installation of the flue it will be necessary to connect the flue spigot and gasket to the outlet using self tap screws provided see diagram 5 6 NOTE The spigot would only be fitted to the top flue outlet where a vertical flue kit or in certain flue bend orientations is incorporated Instructions are supplied with these kits Lift the boiler into position hooking over the top mounting bracket NOTE Anti theft screw kits are available part no s 458113 and 458114 IMPORTANT Secure lower bracket to wall with screw into wall plug already prepared NOTE It will be necessary to move the control box to access the bracket by slackening its retaining screw and swinging it out on its hinge see diagram 5 10
48. tem For an open vented system the boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern fitted ata maximum height of 27 metres above the boiler 2000225230C The cold feed must be 15mm minimum size It is important that the relative positions of the pump cold feed and open vent are as shown in diagram 3 1 Theunrestricted open ventfromthe boiler mustrise continuously to discharge over the feed and expansion cistern 3 5 Domestic Hot Water System General All domestic hot water circuits connections fittings 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 IE The current edition of S 813 Domestic Gas Installations 3 6 Cylinder For all systems supplying domestic hot water the cylinder must be indirect It is recommended that the cylinder be fitted with some form of temperature control OPEN VENTED FULLY PUMPED WATER SYSTEM RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT 7RAR 22mm VENT la MIN 450mm MIN 15mm MINIMUM COLD FEED FEED AND z EXPANSION 5 z CISTERN lm o oc iL 1METRE Y A MIN CYLINDER There must always be a cold water path to the return connection of the boiler Ru 2 HEATING IF REQUIRED 22mm MINIMUM BY PASS WITH LOCKSHIELD VALVE Diagram 3 1 a m p BOILER
49. the burner will go out The automatic lighting sequence will work again when heat is required 6 5 Testing Gas With the boiler on proceed as follows Undo the screw which secures control box see diagram 5 10 Open control box see diagram 5 10 WARNING The multifunctional control and fan operate on mains voltage terminals will be live Test for gas soundness around the boiler gas components using a suitable leak detection fluid in accordance with the current issue of BS6891 Check the main burner gas pressure at least 10 minutes after the boiler has lit refer to Data Label If necessary remove cap then adjustthe gas pressure to obtain the required setting turning screw clockwise to decrease pressure see diagram 6 2 Replace cap Should any doubt exist aboutthe gas rate check it using the gas meter test dial and stop watch at least 10 minutes after the burner has lit making sure that all other gas burning appliances and pilot lights are off 2000225230C 18 Table 2 80FF MIN MED MAX APPROX GAS RATE The gas rates shownin Table 2 are for guidance only dependent on the heat setting Turn the temperature control knob fully anticlockwise to O Isolate from electrical supply Remove the pressure gauge from the test point and refit screw making sure a gas tight seal is made Refit control box and fascia NOTE The fixing holes of the fascia are slotted to allow fine adjustment to al
50. the securing grommet and withdraw the electrical thermistor from its phial see diagram 10 2 Remove thermistor lead from the plastic R clips at rear of case and the cable clips these are located down left hand side of boiler Draw thermistor lead followed by thermistor out through the case grommet Re assembly NOTE When fitting the electrical thermistor make sure that the thermistor and grommet are fully inserted into the phial see diagram 10 2 Take care when re threading as not to damage thermistor Refit the cable clips and the plastic R clips retaining the leads Refit the plastic retaining tag Refit the thermistor lead plug Refit fan assembly IMPORTANT Where the flue has a rear connection from back of casing see diagram 5 6 it is essential to make certain that the flue duct is fully located into the fan elbow until it can go no further enabling the flue duct to make a complete seal when secured 10 3 Safety Temperature Limiter Part No 227038 diagram 10 2 Gain Access as Section 5 2 Remove air pressure switch see diagram 10 6 Remove the electrical connections from the safety temperature limiter device see diagram 10 2 Undo retaining bracket screw and remove together with safety temperature limiter When refitting use the heat sink compound provided Re assembly NOTE Check that safety temperature limiter is secure NOTE Polarity of electrical connections is not important 25
51. tlet or top outlet fixing or Easyfit the terminal restrictor must be fitted This is not fitted for any other flue type arrangement i e extension kits etc NOTE There are three restrictors in the loose items pack use the one stamped A for the Micron 80FF Take the terminal restrictor and position the clamping bracket making sure the clamping bracket nib protrudes inthe slot of the terminal restrictor and secure with locking screw but do not tighten see diagram 4 6 Engage the terminal restrictor on the flue terminal by hooking it over the terminal end and engaging the clamping bracket behind the inner ring of the terminal securing it by tightening the locking screw see diagram 4 6 4 7 Internal Access Flue If accesstothe outside wall is not practical the flue system can be installed from inside Use of the optional wall liner kit is required 4 8 Rear Flue Fixing Fit the self adhesive foam seal provided in the flue pack around the air duct at the position shown in diagram 4 1 Make sure that the ductings do not slope down towards the boiler Make good around the flue outside after installation of boiler IMPORTANT Ifthe wallliner kitis used the self adhesive foam seal included must be used in place of the one supplied with the flue pack see diagram 4 5 for position of self adhesive seal 4 9 Top Side Flue Fixing Make sure that the ductings do not slope down towards the boiler Make good the area around the f
52. uld run for several minutes after remote controls have stopped calling for heat Before using the fault finding chart ensure all wiring is correct and in good condition the pump is not faulty and check the PCB fuse a YES Faulty PCB Replace Does pump continue to run after SL is interrupted NO Y ves Does pump stop after several minutes NO Y ves System satisfactory Diagram 9 2 21 2000225230C 9 Fault Finding 10270 Before carrying out fault finding ensure that gas electricity and water are available to the boiler Ensure that any external controls are calling for heat and circuit water is cold If Reset LED is lit check water system for overheating reset by turning temperature control knob off and on If the LED coding is showing an ignition failure reset the boiler by turning the control knob off and on Do not operate the boiler without combustion chamber front fitted Control Knob at O Yes Power ON at isolation switch Yes No Does the fan run for 10 seconds with RESET LED lit Replace fuse Yes Apply heating demand turn potentiometer clockwise Yes No No Is there an LED sequence Replace PCB Yes Tes Refer to table No No Switch OFF l Does the unit begin to spark Sa ati Remake connections PENNE Ons Mate Restart diagnosis Yes Yes No Refer to table Replace PCB No No Does the burner light Is the Gas turned
53. ure it is in the ON mode NOTE Ifthe programmer is manually switched onthen off when the boiler is cold the boiler may continue to operate for about 30 seconds before switching off Make sure that any remote controls are calling for heat Turn the temperature control clockwise to Max The ignition system will operate to light the boiler After a pre set time if ignition has not taken place the boiler will shutdown To re start the lighting sequence turn the temperature control to 0 then fully clockwise to Max 17 After the burner has lit the Burner on neon onthe control panel will come on Isolate the boiler from the electrical supply Loosen the burner pressure test point screw and connect a suitable pressure gauge see diagram 6 2 Replace control box Switch on the electrical supply to the boiler FASCIA 7318 SECURING __ w SCREWS CONTROLS Md Diagram 6 1 MULTIFUNCTIONAL ee CONTROL eo GAS 5 PRESSURE ADJUSTMENT SCREW ON BURNER PRESSURE TEST POINT GAS COCK OFF NOTE Do not adjust any other setting screws Diagram 6 2 2000225230C 6 Commissioning 6 4 Testing Electrical Turn the boiler temperature control knob fully clockwise to the maximum setting which is approx 82 C 180 F The lighting sequence is automatic as follows The fan will operate for 10 seconds prior to the start of the ignition sparks the gas valve soleno
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