Instructions for Use Installation and Servicing
Contents
1. MINIMUM SITING DIMENSIONS MINIMUM FOR FANNED FLUE SPACING TERMINALS POSITION in mm A DIRECTLY BELOW ABOVE OR mOoOQO W mul 0161M HORIZONTALLY TO AN OPENING AIR BRICK OPENING WINDOWS AIR VENT OR ANY OTHER VENTILATION OPENING 300 BELOW GUTTER DRAIN SOIL PIPE 75 BELOW EAVES 200 BELOW A BALCONY OR CAR PORT 200 FROM VERTICAL DRAIN PIPES AND SOIL PIPES 75 FROM EXTERNAL CORNERS 300 ABOVE ADJACENT GROUND OR BALCONY LEVEL 300 FROM A SURFACE FACING THE TERMINAL 600 FACING TERMINALS 1200 FROM OPENING DOOR WINDOW IN CAR PORT INTO DWELLING 1200 VERTICAL FROM A TERMINAL 1500 HORIZONTALLY FROM A TERMINAL 300 FROM INTERNAL CORNERS 25 Diagram 2 1 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 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 If the position of the boiler is such t2. Diagram 4 3 221964D 4 Flue and Appliance Preparation 4 3 Flue Preparation Allflue assemblies are designed for internal installation optional wall liner is required given that there is sufficient clearances opposite to the flue for the installation of the flue 0098M If there is insufficient clearance the flue can be installed from outside For a wall thickness up to 300mm provided that there is sufficient space and the optional wall liner kitis used the flue can be fully 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 kit irrespective of wall thickness 4 4 Rear and Side Flue Application et O Select the boiler location and flue application with due regard oe to the terminal position l SIDE FLUE Take the template from the boiler pack and temporarily position it on the wall making sure that the minimum clearances are maintained see diagram 1 2 For a rear flue mark the position of the flue as diagram 4 4 For a side flue extend the centre line horizontally left or right to the corner of the adjacent surface where the flue is required to exit to outside Mark the position of the centre of the flue and ae BOILER boiler as diagram 4 4 FLUE CENTRE LINE CENTRE LINE REAR FLUE Diagram 4 4 a 3 3 4096
3. ener ne G H O AL top BOILER MOUNTING TEMPLATE seats ee otto BOILER CENTRELINE FLUE FLUE CENTRELINE BOILER CENTRELINE CENTRELINE se MOUNTING ql j MOUNTING Ro BRACKET J BRACKET FIXING POINTS 3 i i Q Diagram 4 5 221964D 14 4 Flue and Appliance Preparation 4 5 Flue Hole Cutting Having marked out the flue centre cut a hole for the flue using preferably a 115mm minimum core drill 4 6 Wall Mounting Bracket Reposition the template making sure of dimensional alignment with the flue hole Mark the boiler fixing points and mounting bracket position see diagram 4 5 Drill holes and plug to suit No 12x2in wood screws fit the screws allowing sufficient clearance about 5mm to accept the swing brackets see diagram 4 5 Secure the mounting bracket to the wall with No 12x2in wood screws and plugs see diagram 4 5 4 7 Flue Duct Mark the duct to the length required this length allows for expansion see diagram 4 6 for rear flue and diagram 4 7 for side flue then cut square and remove any burrs 6833 FLUE Diagram 4 6 v 0 FLUE R DUCT ON K i 7 BOILER CENTRE LINE Pa l P i bas ry Diagram 4 7 O N 0 LONG FLUE Sn TERMINAL ea ey STANDARD FLUE Diagram 4 8 15 221964D 4 Flue and Appliance Preparation 4 8 Air Duct Terminal Mark the duct length see diagra
4. low worm 221964D 12 04 Quality through design Instructions for Use Installation and Servicing Tobeleftwiththe user YUE 60FF G C No 41 047 56 Fanned Flue Boiler The code of practice for the installation commissioning amp servicing of gas fires and wall heaters 4098 benchmark D BS 6332 BS 5258 This is a Cat I Appliance Reference in these instructions to British Standards and Statutory Regulations Requirements apply only to the United Kingdom For Ireland the rules in force 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 the Glow worm Customer Service number 01773 828100 Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of
5. MULTI FUNCTIONAL CONTROL k Remove red link between 9 and SL when fitting a time control etc If no switch is fitted link will make the circulation pump run constantly L fF CHASSIS SES EARTH CIRCULATON PUMP Jm E br RY on NOTE 7 o l er Sees L 230 50Hz aN p PERMANENT j HOH aly MAINS was Wicus EJ SUPPLY 1 FUSED AT3 AMP SWITCH CONTROL TIME SWITCH PROGRAMMER ETC if fitted OVERHEAT CUTOFF Diagram 9 7 221964D 32 10 Replacement of Parts NOTE 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 indicator slot to be vertical 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 8 1 10 2 Control Thermostat diagram 10 1 and 10 2 Remove and support the electrical control box refer to Section 5 6 Remove the control knob Remove the electrical connections from the thermostat body Release the thermostat body by unscrewing the two screws and shakeproof washers in the front of the control box Remove the split pin and withdraw the thermostat phial from its pocket Release the capillary from the base and plastic retaining clip
6. 16 4 Flue and Appliance Preparation IMPORTANT If the wall liner kit is used the self adhesive foam seal included in the wall liner kit must be used in place of the one g supplied with the flue pack see diagram 4 11 for position of self 9 adhesive seal 4 12 Flue Assembly Installation If the boiler is not to be fitted for some time cover the hole in the wall On limited access installations push the flue assembly into the hole such that it is within the wall and does not stick out into the room see diagram 4 12 Do not push the flue assembly too far into the hole as it has to be pulled back into the boiler and secured GASKET 4 13 Internal Access Flue PRE ATTACHED If access to the outside wall is not practical the flue system can be installed from inside Use of the optional wall liner kit is required Diagram 4 12 FOAM 2 WITH WALL LINER KIT ONLY ay Mees FOAM S oy I gt LI 47 7q l gt B Se i N a REAR FITTING Diagram 4 13 WALL THICKNESS UP TO 300mm z 3 WALL THICKNESS OVER 300mm Lae Diagram 4 11 SIDE FITTING Diagram 4 14 17 221964D 5 Boiler Installation 5 1 Boiler Preparation With the boiler still in the bottom tray slide the controls cover upward and remove it as shown in diagram 5 1 Remove the front cover by undoing the wing nut nut and washer lift the front cover off see diag
7. Faulty PCB Replace Does pump continue to run after NO SL is interrupted YES Does pump stop after several NO minutes YES System satisfactory FOR FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS ONLY Diagram 9 3 29 221964D 9 Fault Finding N g N bk BLACK or ORANGE eR br BROWN w WHITE bl BLUE r RED p PURPLE y YELLOW k Red Link must be fitted between SL and 9 L RED LINK sH 17 P n SPARK P or ELECTRODE O br Ez bl etl h 1 4 4 YELLOW FUSE LINK TYPE F1 amp F2 F1A ki 0 CONTROL STAT X N Q Q Q X N PILOT SOLENOID bl bk bl N MAIN SOLENOID N Yellow Link fitted to bridge out the overheat cutoff PUMP WIRED INTO CENTRAL HEATING SYSTEM REMOTE CONTROLS A AIR PRESSURE SWITCH CONNECTIONS MAIN TERMINAL STRIP CONNECTIONS O CONTROL THERMOSTAT CONNECTIONS PRINTED CIRCUIT BOARD CONNECTIONS GRAVITY DOMESTIC HOT WATER AND FULLY PUMPED CENTRAL HEATING Diagram 9 4 5741 bk BLACK br BROWN b BLUE r p PURLPLE or ORANGE w WHITE RED y YELLOW SPARK ELECTRODE TYPE F1 amp F2 F1A PILOT SOLENOID bk MAIN SOLENOID Remove red link between 9 and SL when fitting a time control etc if no switch is fitted link will make the circulation pump run constantly A AIR PRESSURE SWITCH CONNECTIONS MAIN TERMINAL STRIP CONNECTIONS CONTROL THERMOSTAT
8. SEAL Right hand illustrated Diagram 10 2 ELECTRICAL PLUGS iB BOILER a THERMOSTAT ELECTRICAL CONNECTION NO 3 YELLOW CABLE CHASSIS EARTH CONNECTION SECURING SUPPORT Ss eenie SCREW 2 POST 4 CONNECTION SATION MAIN i LEAD TERMINAL STRIP X KN PLASTIC a CLIP SC ae SAC VA p z ENN ELECTRICAL CONNECTION BLUE CABLE N PLUGS ELECTRICAL CONNECTION BROWN CABLE SL Diagram 10 2A 10 4 Control Board PCB diagram 10 2A Release the control box refer to Section 5 6 Disconnect the three electrical plugs and ignition lead Release the cables from the plastic retaining clip then disconnect the cables from the PCB to the main terminal strip control thermostat and earth connection Release the main terminal strip and plastic label Carefully pull the board away from its supports When refitting refer to wiring diagram 9 6 or 9 7 as appropriate 10 5 Pilot Burner and Pilot Injector Proceed as Section 8 3 and 8 5 221964D 10 6 Electrode Proceed as Section 8 3 and 8 5 Gain access as Section 5 6 to remove lead from control box 10 7 Multifunctional Control diagram 10 3 Disconnect the pilot supply by unscrewing the tubing nut at the multifunctional control take care as there is a restrictor on the pilot pipe Disconnect the electrical plug Support the multifunctional control remove the four extended screws from the flanged connections at the
9. W All replacement parts REGISTER YOUR GLOW WORM APPLIANCE All call out charges CALL 0800 073 2142 Glow worm low worm Tel 01773 828100 Nottingham Road Belper Derbyshire DES6 1JT General Sales enquiries Tel 01773 824141 Fax 01773 820569 www glow worm co uk S E R V_ I C CE Fax 01773 828070 Important Information TESTING AND CERTIFICATION This boiler is tested and certificated 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 see Section 1 4 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 Regulatioon 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 the Laws of the Member States relating to the electrical equipment designed for use withi
10. and resistance to earth checks must be repeated using a suitable multimeter Refer to neon indicators An Aid to Fault Finding diagram 9 1 Boiler Fault Finding diagram 9 2 Pump Overrun Fault Finding diagram 9 3 the Functional Flow diagram 9 4 Gravity Domestic Hot Water and Fully Pumped Central Heating diagram 9 5 Fully Pumped Open Vented or Sealed Water System the Pictorial Wiring diagram 9 6 Gravity Domestic Hot Water and Fully Pumped Central Heating and diagram 9 7 Fully Pumped Open Vented or Sealed Water System 9 2 Electrical Supply Failure Failure of the electrical supply will cause the burner to go out Operation will normally resume on the restoration of the electrical supply If the burner does not relight after an electrical supply failure the overheat device may need resetting Remove the control cover see diagram 6 6 and push the reset button on the front of the control box see diagram 6 1 If the cutoff operates at any other time press the reset button and the burner should relight If the fault persists refer to fault finding chart NOTE the pump may run for several minutes when power is first applied regardless of a call for heat s eT So Neon Indicators An Aid to Fault Finding q THE NEON INDICATORS ARE AN AID TO FAULT FINDING ONLY FAILURE OF ANY OF THE NEON INDICATORS DOES NOT WARRANT THE v REPLACEMENT OF AN OTHERWISE SATIS
11. current issue of BS7478 for guidance 6 10 Protection Against Freezing If the boiler is to be out of use for a period of time during severe weather conditions we recommend thatthe whole of the system including the boiler be drained off to avoid the risk of freezing up 6 11 Operational Checks and Completion Adjust the boiler thermostat and any system controls to their required settings Do not attempt to adjust the thermostat calibration screw Operate the boiler again on full service and check that the balancing is satisfactory making adjustments as necessary 221964D 24 TOP SEAL Q SIDE SEAL NOTE MAKE SURE OF CORRECT ENGAGEMENT WING NUT R WASHE Diagram 6 5 oO lt CONTROLS COVER SLIDERS Diagram 6 6 Fit the front cover by hooking it under at the top and securing with the wing nut washer and nut previously removed see diagram 6 5 Fit the controls cover by hooking into the sliders and pushing it back as far as it will go see diagram 6 6 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 that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and service
12. pump cold feed and open vent are as shown in diagram 3 2 The unrestricted open vent from the boiler must rise 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 ForlE The current edition of S 813 Domestic Gas Installations The domestic hot water service must be in accordance with the N oo oO 1000 OR tees 62 23 750 3 Bo L en 500 f ae 250 0 Flow rate litres minute The insertion point indicates the flow rate required to achieve 11 C temperature difference Diagram 3 1 current issue of BS5546 refer also to the current issue of BS6700 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 3 7 Gravity Domestic Hot Water with Pumped Heating Important If domestic hot water is to be provided by a gravity circulation to the cylinder the blanked off connections must be opened and used using 22x28mm connections see diagram 3 3 3 8 Fully Pumped Heating and Domestic Hot Water The connections for this type of system MUST be as shown in diagram 3 2 and 3 4 3 9 Inhibitor Attenti
13. systems only Is neon 2 lit UA E A e connection check continuity of yellow link For fully NO f pumped systems check overheat reset YES f YES If satisfactory replace overheat device YES fis there 230V BER Replace thermostat between on thermostat and N p NO NO ch inted circui Is there 230V between eck yellow cable between printed circuit Is neon 3 lit Nic on air pressure switch and N gt board and air pressure switch If satisfactory replace printed circuit board YES f YES Is there 230V between C on air pressure switch and N NO H Replace air pressure switch YES NO Does fan run Is there 230V between motor connections on fan YES 1 YES NO Replace fan Isolate electrical supply test fan harness continuity If satisfactory replace printed circuit board YES i aH Does fan Hunt p Replace printed circuit board NO f YES Is there 230V between N O on air Inspect air tubes for leaks kinks and correct i __ fitting If satisfactory replace faulty air pressure pressure switch and N switch Is there 230V between pilot NO Is Neon 4lit multi functional control solenoid ____ Isolate supply
14. test harness continuity NO blue and brown connections If satisfactory replace printed circiut board YES YES NO Is there a spark at pilot burner Check lead continuity and inspect electrode and gt lead for damage YES ae NO Check for pilot jet blockage incorrect electrode Does pilot light dg adjustment If satisfactory replace multi functional control VES YES NO Inspect electrode lead connection rT Pay for poor contact Check electrical supply f x With pilot lit does Spank stop polarity and correct if necessary If satisfactory replace printed circuit board NO NO Is there 230V between main Does main burner light 4 multi functional control solenoid black p Isolate supply test harness and replace as required YES and blue cables MAIN TERMINAL STRIP YES System satisfactory Replace multi functional control CONTROL THERMOSTAT Diagram 9 2 221964D 28 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility The pump should 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 F2 NO Does the pump run when SL is applied YES
15. then remove it from the split grommet Release the capillary from its clips Remove the thermostat complete from the boiler Re assembly NOTE When fitting the thermostat make sure that the thermostat phial is covered with heat sink compound and then fully inserted into the phial pocket and that the capillary is within the gland seal see diagram 10 2 Remake the electrical connections There must be no kinks or sharp bends in the capillary 10 3 Over Heat Cutoff Device diagram 10 1 10 2 and 10 2A Release the control box as Section 5 6 Remove the overheat cutoff electrical connections Disconnect the air pressure switch plug from the PCB Remove the locking nut from the overheat cutoff Release the capillary from the retaining clips then remove it from the split grommet Slacken the bracket and remove the phial from the pipe When refitting use the heat sink compound provided and make sure that the phial is correctly fitted into the groove on the pipe 33 CONTROL THERMOSTAT SHAKEPROOF WASHERS AND SCREWS ELECTRICAL CONNECTIONS 5754 CONNECTIONS YELLOW amp Diagram 10 1 221964D 10 Replacement of Parts PHIAL RETAINING BRACKET SECURING SCREW OVERHEAT CUTOFF DEVICE PHIAL 4103 CONTROL THERMOSTAT PHIAL SPLIT PIN L RETAINING CLIP NOTE All capillaries and cable should be situated within the Gland seal GLAND
16. to O Off To relight turn the control thermostat knob to any position between MIN and MAX For longer periods turn the control thermostat knob fully anti clockwise to O Off and switch off the electrical supply to the boiler To relight follow the lighting sequence given above 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 For the position of the serial number see diagram 1 1 General Data FLOW GRAVITY a RETURN PUMPED GRAVITY 6758 a RETURN 4 WATER CONNECTIONS J 22mm COPPER PIPE GAS CONNECTIONS RC 2 in BSPT SIDE ELEVATION All dimensions are given in millimetres except as noted FRONT ELEVATION A B C D E F G 70 300 63 146 78 360 146 H J K L M N P 87 700 574 14 60 130 38 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 When used on an open vented system domestic h
17. CONNECTIONS PRINTED CIRCUIT BOARD CONNECTIONS FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEM Diagram 9 5 221964D 30 9 Fault Finding BLUE SS BLACK E FAN BROWN SD GREEN YELLOW Al 3 ORANGE i S PURPLE A RED YELLOW L gt WHITE AIR PRESSURE SWITCH OA P N SEQUENCE BOARD FUSES 9g y F1 amp F2 F1A g y Dams ot eet mone Sfi i b aa or Ir Ensure RED LINK connected IB a i i between 9 and SL g Oo g 2 3 PLUGS d E L b ny 230 50Hz MAINS E SUPPLY y L FUSED p AT 3 AMP Ww J y Pee 8 OVERHEAT CONTROL THERMOSTAT CUTOFF 5859 GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING MULTI FUNCTIONAL CONTROL L fr CHASSIS ES EARTH G D H W amp pumped central heating the Yellow link must be fitted to bridge out the overheat cutoff lt Pump must be wired into central heating system remote controls and not to control box Diagram 9 6 221964D 9 Fault Finding BLUE BLACK BROWN GREEN YELLOW ORANGE PURPLE RED YELLOW PRESSURE SWITCH CHASSIS WW L g y j g y SEQUENCE ia b CONTROL THERMOSTAT ZR RLF sn FAN ST ie Sy A gt gt EARTH l AU il Cqancacn RE g y 5860 FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEM
18. FACTORY PRINTED CIRCUIT BOARD PCB NO Is neon 1 lit 1 Fault with mains supply or PCB fuse YES NO Overheat cut off device tripped or Is neon 2 lit Ipa thermostat overheat cut off device faulty see detailed fault finding chart YES NO Air flow proving fault that is fan or air Is neon 3 lit 1a pressure switch see detailed fault finding chart YES No Igniti ilot or fl ing fault it gnition pilot or flame proving fault IS neona see detailed fault finding chart YES Ng Multi functional control harness problem Is main burner operating gt see detailed fault finding chart YES System satisfactory NEON INDICATORS Diagram 9 1 27 221964D 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat Check the gas supply is free of obstructions and purged of air Check the overheat cutoff has not operated for fully pumped systems only Isolate the electrical supply and physically check ALL cables connections and the printed circuit board fuse Check the air tubes to the air pressure switch Switch on the electrical supply and check for correct polarity Turn the boiler thermostat to its maximum setting Also check fuses Is neon 1 lit peal araen I T pa Correct power supply problem YES YES NO For gravity domestic hot water
19. IRED 15mm MINIMUM BY PASS WITH LOCKSHIELD VALVE Diagram 3 2 BOILER wt A S oz S Q Wek a gt 25 gt lt SF q 2 aa SW a 6 Targ z A O 5 iL E 28mm ty PIPE x COMPRESSION JOINT 22mm VENT 15mm COLD FEED INDIRECT CYLINDER Shown with 0090M 1m MIN recommended 27m Max thermostat and valve HEATING SYSTEM 28mm VIEWED FROM EE ONT REFER TO BS 5546 Diagram 3 3 S NOTE When cutting leave sufficient length for fittings 5 FLOW RETURN 22mm PIPE 22mm VENT amp 15mm COLD FEED TO BE FITTED IN ACCORDANCE WITH BS 5449 k INDIRECT CYLINDER 1metre Min IF REQUIRED o ALTERNATIVE BYPASS 15mm 27 metres SYSTEM MIN WITH Max CONTROL LOCKSHIELD VALVES VALVE HEATING SYSTEM FULLY PUMPED CIRCULATION SYSTEM DIAGRAMMATIC 6456 22mm FOR COMBINED FEED amp VENT TO BE FITTED IN ACCORDANCE WITH BS 5449 INDIRECT CYLINDER 27 metres BYPASS 15mm Max MIN WITH LOCKSHIELD HEATING SYSTEM o ALTERNATIVE SYSTEM CONTROL VALVES FULLY PUMPED CIRCULATION BYPASS DIAGRAMMATIC Diagram 3 4 221964D 10 3 Water Systems 3 12 Expansion Vessel 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 see diagram 3 5 unless laid down differently by the
20. LET ILLUSTRATED z PLATE lt FLUE BX MANIFOLD ENS SPIGOT r FAN DUCT S tm 14 EXTENSION LA ws lt Diagram 5 7 221964D 20 5 Boiler Installation 5 10 External Controls Make sure that the supply cable and all external cables are secured and away from hot surfaces GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING SEE DIAGRAM 5 9 FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS SEE DIAGRAM 5 10 5 11 Testing Checks to ensure electrical safety must be carried out by a competent person 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 on the controls scheme used with the boiler SECURING SCREWS 2 5739 Diagram 5 8 CABLE CLAMPS GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING L CHASSIS oS EARTH Important NOTE On G D H W amp pumped central heating the Yellow link must be fitted to bridge out the overheat cutoff central heating system remote controls and NOT to control Ensure RED LINK connected between 9 and SL L 230 50Hz N MAINS SUPPLY T CABLE E FUSED Make sure that the red link is connected between L AT 3 AMP terminals SL and 9 on the term
21. LPER DERBYS DE56 1JT ULTIMATE 60FF 2000462026 230V 50Hz 56W Fusedat3A TYPE C12 C32 For use on G20 gas only Supply pressure 20 mbar This boiler is intended exclusively GC No 41 047 56 to be installed on a gas supply with a governed meter CE 0086 G B IE 86 A0 007 HEAT INPUT NETT Q HEAT OUTPUT 16 12 BS 5258 P 55000 Cat Iz4 HOT BURNER 10 8 EN437 PRESSURE 44 5 1 Position 48 against setting SERIAL No Diagram 1 2 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 to the currentissue of BS6500 Table 16 not less than 0 75mm 24 0 20mm 1 7 Contents of Packaging The boiler is delivered in one pack refer to Section 4 1 for contents 1 8 Water System This boiler may be fitted to an open vented or a sealed water system 1 9 Drain System A drain tap must be provided at the lowest points of the system which will allow the
22. W SERVICIN VALVE HEATING G PRESSURE SYSTEM REDUCING SUPPLY R STOP VALVE HOSE DOUBLE CHECK ope nies VALVE ASSEMBLY Diagram 3 6 4 Flue and Appliance Preparation 4 1 Unpacking Open the carton check the items supplied against the boiler pack contents list on the flap and diagram 4 1 4 2 Flue Position and Length Determine flue application length and terminal position before starting Refer to diagram 4 2 or 4 3 If you are using a Flue Bend or a Vertical Flue Kit please follow the instructions supplied with that kit To make a neat finish to the flue outlet a flue collar kit part No 443286 with instructions is available Please NOTE the use of this collar will mean that the flue lengths will need to be altered full instructions are given in the kit NOTE If required an optional Wall Liner Kit Part No 900862 is available complete with fixing instructions D LOOSE P ITEMS PACK A WALL aa ED MOUNTING BRACKET CARTON TOP INSTRUCTIONS u a Diagram 4 1 13 6827 Standard Flue terminal illustrated REAR FLUE LENGTHS Distance R Wall thickness STD 75mm to 505mm 1M 75mm to 1015mm 2M 75mm to 2015mm 3M 75mm to 2995mm Diagram 4 2 foe N Ko Standard Flue terminal illustrated SIDE FLUE LENGTHS Distance S External wall face to boiler case STD 81mm to 513mm 1M 81mm to 1023mm 2M 81mm to 2023mm 3M 81mm to 3003mm
23. agram 2 1 For lreland the minimum distances for flue terminal positioning must be those detailed in 1 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 respect to 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 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 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 a minimum of 50mm clearance from any part of the terminal and be central over the terminal A suitable guard reference Type K3 can be obtained from Tower Flue Components Ltd Morley Road Tonbridge Kent TN9 1RA 221964D Under Car Port etc
24. an existing system the local authority must also be advised 3 LITRES 0 66 gals MAKE UP BOTTLE if required HEATING CIRCUIT RETURN Make up alternatives AUTO l i 1AIR NON RETURN VENT VALVE FLOW N SA AIR RELEASE A POINT FILLING POINT 7 IF REQUIRED 15mm min LOCKSHIELD VALVE CIRCULATING SAFETY VALVE PUMP PRESSURE GAUGE BOILER EXPANSION VESSEL Diagram 3 5 221964D 3 Water Systems 3 16 Filling a Sealed Water System Provision for filling the system at low level must be made Three methods are shown in diagram 3 6 There mustbe no permanent connection to the mains water supply even through a non return valve 3 17 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 see diagram 3 5 Alternatively provision for make up can be made by a filling loop 221964D 12 METHOD 1 COMBINED sea CHECK VALVE HEATING TEMPORARY AND VACUUM SYSTEM E as HOSE SERVICING UNIONS VALVE he SUPPLY STOP SUPPLY VALVE PIPE METHOD 2 TEMPORARY HOSE LA I l HEATING DOUBLE CHECK SYSTEM VALVE ASSEMBLY SERVICING aaia VALVE UNIONS hans SUPPLY STOP SUPPLY VALVE PIPE METHOD 3 CISTERN OVERFLO
25. an the heat exchanger flueways with a suitable stiff brush Remove the paper together with any debris 25 8 3 Main Burner Disconnect the pilot pipe union connector Remove the pilot burner securing nut and shakeproof washer together with the pilot shield Remove the pilot burner assembly taking care not to damage the electrode and lead assembly see diagram 8 3 Remove the wing nut from the burner support bracket see diagram 8 4 4083 SECURING SCREW REAR 2 KEYHOLE SLOTS SLACKEN SCREW FLUEHOOD GASKET SECURING SCREW 2 Diagram 8 1 BAFFLE 5855 Diagram 8 2 221964D 8 Servicing Remove the main burner from the main injector at the rear Raise the burner up and forward easing the pilot pipe down to clear take care notto damage the combustion chamber insulation or the pilot burner assembly Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly making sure that all the burner ports are clear and unobstructed NOTE On refitting and after cleaning the heat exchanger make sure the main burner is fitted correctly that is located on the main injector and horizontal 8 4 Main Injector With the main burner removed the main injector can be inspected and cleaned as necessary see diagram 8 5 If removing for cleaning do not use a wire or sharp instrument on the hole Use alittle suitable sealant on the external thread when refitt
26. current issue of British Standard 6332 Part 1 invoking the current issue of BS5258 Part 1 for performance and safety It is therefore important that no alteration is made to this boiler without permission in writing from Glow worm Any alteration that is not approved by Glow worm could invalidate the B S I Certification of the boiler warranty and could also infringe the current issue of the Statutory Requirements 1 5 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 using the pressure drop method and suitable leak detection fluid purge in accordance with the current issue of BS6891 1 6 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 issue 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 BS 6891 In IE this is the current edition of 1 S 813 Domestic Gas Installations 221964D 0 S a HEPWORTH HEATING LTD hy r Glow worm BE
27. d at regular intervals The frequency of servicing will depend upon the particular installation and usage butin 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 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 and the Benchmark logbook with the user 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 1 S 813 8 Servicing 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 NOTES 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 It is th
28. e Law that any servicing is carried out by a competent person Before servicing turn off the gas and isolate the electrical supply to the boiler After completing a service always test for gas soundness and carry out functional check on controls Unless stated otherwise all parts are replaced in the reverse order to removal 8 1 Access Refer to diagram 6 6 and slide the controls cover forwards and off Remove the outer case see diagram 6 5 NOTE As an aid to Servicing the air pressure switch tube connection can be used to obtain a products of combustion reading Remove the RED tube from the connection on the air pressure switch and insert the analyser probe into the tube Switch on the electrical supply to operate the fan and turn on the gas supply On completion of the test switch off the electrical supply and the gas supply and reconnect the red tube to the air pressure switch 8 2 Cleaning Heat Exchanger Flueways Disconnect the air pressure tubes see diagram 5 4 Remove the blue and red electrical connections from the fan see diagram 5 4 Remove the fan complete with the fan duct extension taking care not to damage the gasket see diagram 5 4 and 5 7 Remove the flue hood noting that there are keyhole slots at the rear see diagram 8 1 Remove the combustion chamber cover Remove the burner as Section 8 3 Place a sheet of paper in the base of the combustion chamber Remove the baffles see diagram 8 2 Cle
29. e and route it to outside the building so that any discharge can be seen but will not cause injury to persons damage to property or any electrical installation 5 5 Gas Connection Make the gas connection to the Rc in gas service cock see diagram 6 1 Check for leaks using a suitable leak detection fluid The whole of the gas installation including the meter should be inspected tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition of I S 813 Domestic Gas Installations 5 6 Control Box Removal Remove the electrical control box securing screws see diagram 5 8 Slide the box forwards and release hook it onto the lip bracket at the front see diagram 5 8 5 7 Electrical Connection WARNING This boiler must be earthed Take care not to damage any internal wiring and capillaries Take the plastic cable retaining clip from the loose items pack peel off the backing paper and position it in a suitable place to secure the incoming cable SWING BRACKET SECURING REWS 2 NOTE ee PIPES REMOVED FOR CLARITY MOUNTING BRACKET Diagram 5 3 19 Using heat resistant 85 C cable of at least 0 75mm 24 0 2mm to the current issue of BS6500 Table 16 and of a suitable length thread through the cable clamps secure into the plastic clips and connect to appropriate terminals see relevant diagram 5 9 or 5 10 Standard colours are brown l
30. e 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 INSTRUCTIONS Introduction 3 FOR USE Lighting the Boiler 4 INSTALLATION General Data 1 5 Flue amp Ventilation 2 8 INSTRUCTIONS Water Systems 3 9 Flue and Appliance Preparation 4 13 Boiler Installation 5 18 Commissioning 6 22 Instructions to User 7 25 SERVICING Servicing 8 25 Fault Finding 9 27 skian Replacement Parts 10 33 Spare Parts 11 38 221964D 2 Instructions for Use Introduction WARNING It is important that the case not the controls tray is not disturbed or removed other than for servicing by a competent person The user shall not interfere with or adjust sealed parts Please read these instructions and follow them carefully for the safe and economical use of your boiler The Ultimate FF 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 control thermostat The Gas Safety Installation and Use Regulations In your interest and that of gas safety it is the law that ALL gas appliances are installed by a competent person in accordance with the above regulations Gas Leak or Fault Turn off the gas emergency control valve immediately Eliminate all sources of ignition i
31. e gauge should show at least 0 7bar anything less than this figure could indicate a leak and you MUST contact your installation servicing company If there is any doubt about the boiler being full of water consult your installation servicing company ALL SYSTEMS Turn the electrical supply on to the boiler and check that all remote controls are calling for heat To Turn the Boiler On Remove the controls cover by withdrawing it forward and off see diagram 1 Turn the control thermostat knob clockwise to any position between MIN and MAX The maximum temperature setting is about 82 C 180 F see diagram 1 The boiler lighting operation is now automatic as follows The fan operates followed by an ignition spark until the pilot is lit When the pilot is alight the ignition system switches off and the main burner lights The flames can be seen through the viewing window see diagram 1 The main burner will remain alight until switched off by the control thermostat or any remote control If the boiler is switched OFF by hand wait at least 30 seconds before switching on again When the boiler switches off both the pilot and main burner go out The automatic lighting sequence will operate again when heat is required Refit 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 thermostat knob anti clockwise
32. e smoking blowlamps hot air guns etc Do not operate 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 remove the controls cover and press the reset button refer to diagram 1 Overheat Safety Cutoff If the overheat safety cutoff device operates on any other occasion than an electrical supply failure press the reset button as in Electrical Supply Failure If the overheat operates again turn the appliance off and contact your installation servicing company 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 If this appliance is installed in a rented property in the UK there is a duty or 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 y
33. ected tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition of I S 813 Domestic Gas Installations Check the main burner gas pressure at least 10 minutes after the boiler has lit refer to Data Label If necessary adjust the gas pressure to obtain the required 23 4138 SECURING SCREW 4 VIEWING WINDOW Diagram 6 3 10 to 20mm FLAME LENGTH NOTE PILOT SHIELD REMOVED FOR CLARITY 4139 Diagram 6 4 setting turning screw clockwise to decrease pressure see diagram 6 2 Should any doubt exist about the 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 221964D 6 Commissioning Turn the control thermostat knob fully anticlockwise to Off Remove the pressure gauge from the test point and refit screw making sure a gas tight seal is made When the control thermostat is turned to the Off 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 Refit the electrical controls box see diagram 5 8 NOTE The neon indicator lights on the printed circuit board are an aid to fault finding for details refer to S
34. ection 9 6 6 Testing Open Vented System Allow the system to reach maximum working temperature and examine for water leaks There should be no undue noise in the system and no pumping over of water or entry of air at the open vent above the feed and expansion cistern All systems The boiler should then be turned off and the system drained off as rapidly as possible whilst still hot 6 7 Adjustment Fully Pumped Open Vented and Sealed Water Systems When commissioning the system the boiler should first be fired with the bypass fully closed on full service that is central heating and domestic hot water Adjust the pump to the system design setting then balance the system Having achieved a satisfactory condition operate the boiler with the bypass fully closed on minimum load normally this will be central heating only with one radiator in the main living area operating The bypass valve should be gradually opened to achieve a temperature difference no greater than 20 C between the flow and return UNDER NO CIRCUMSTANCES SHOULD THIS VALVE BE LEFT IN THE FULLY CLOSED POSITION 6 8 Sealed Water Systems ONLY Adjust the system to initial design pressure The set pointer on the pressure gauge should be set to coincide with the indicating pointer 6 9 Thermostatic Radiator Valves If thermostatic radiator valves are fitted care must be taken to ensure that an adequate flow rate through the boiler when they close refer to the
35. entire system boiler 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 bottom right hand side of the heat exchanger Cover the controls to avoid water damage If required remove the combustion chamber front cover to improve access 1 10 Safety Valve A safety valve need not be fitted to an open vented system 1 General Data 1 11 Location This boiler is not suitable for outdoor installation This boiler is suitable for installation in bathroom zones 2 and 3 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 In GB this is the current E E WIRING REGULATIONS and BUILDING REGULATIONS In IE reference should 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 12 Boiler Clearances Refer to diagram 1 3 This boiler must be positioned so that at least the minim
36. hat it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422 Itis recommended that a frost protection thermostat be fitted 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 can be found from diagram 3 1 High resistance microbore systems may require a higher duty pump 3 3 Bypass Fully Pumped and Sealed Water System A bypass is usually unnecessary on systems using a 3 port diverter valve since one port will remain in the open position at all times 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 atemperature difference greater than 20 C between the flow and return 3 4 Water System For an open vented system the boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern fitted at a maximum height of 27metres above the boiler The cold feed must be 15mm minimum size It is important that the relative positions of the
37. he elbow and assemble to the fan as shown in diagram 5 6 Do not secure at this point with the screw Position the fan assembly and engage the fan duct extension over the flue manifold Make sure by pushing the flue duct extension that a secure seal is made Mark the final position of the fan duct extension through the screw hole on the elbow remove the assembly and secure with the screw as diagram 5 6 Secure the elbow to the fan outlet with the Jubilee clip For rear outlet cut and fit the fan duct extension as diagram 5 6 Secure with the Jubilee clip Fit fan assembly by engaging the fan duct extension over the flue manifold spigot see diagram 5 7 Secure the fan assembly with the screws previously slackened and removed Reconnect the blue and red electrical connections to the fan the polarity of the connections is not important Reconnect the air pressure switch tubes as shown in diagram 5 4 221964D 18 4115 CONTROLS COVER Diagram 5 1 ap 22mm HEATING a RETURN 22mm GRAVITY 22mm HEATING DOMESTIC HOT FLOW WATER STUB A 22x28 GRAVITY NOTE When cutting leave sufficient length for fittings Diagram 5 2 5 Boiler Installation 5 3 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 4 Safety Valve Discharge Fit a suitable discharge pipe to the safety valv
38. hed The boiler must only be connected to a 230V 50Hz supply protected by a 3A fuse All system components shall be of an approved type and shall be connected in accordance with the current issue 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 BS 6891 In IE this is the current edition of 1 S 813 Domestic Gas Installations Wiring to the boiler must be PVC insulated type to the current issue of BS6500 Table 16 not less than 0 75mm 24 0 20mm The colours of three core flexible cable are Brown live Blue neutral Green yellow earth As the markings on your plug may not correspond with these colours continue as follows The cable coloured blue must be connected to the terminal marked N or black The cable coloured brown must be connected to the terminal marked L or red The cable coloured green yellow must be connected to the terminal marked E or green or the earth symbol 0081M 500mm Additional clearances may be required for installation SIDE OR REAR FLUE 5mm Diagram 2 221964D To Light the Boiler WARNING Sealed Systems Do not operate the boiler wthout water A sealed water system must be filled and pressurised by a competent person Only light the boiler when you are sure that the system has been filled and pressurised The pressur
39. inal block as F diagram 5 9 and 9 6 Diagram 5 9 FULLY PUMPED aCe OPEN VENTED CLAMPS OR SEALED WATER SYSTEM Any external controls must only be wired to interrupt the red link between terminals SL and 9 See relevant wiring diagrams for either a sealed water system or fully pumped open vented diagram 5 10 and 9 7 PR EARTH ES SWITCH CONTROL TIME SWITCH PROGRAMMER ETC when fitted remove red link CIRCULATON PUMP 230 50Hz MAINS SUPPLY FUSED AT 3 AMP Hm z re Diagram 5 10 21 221964D 6 Commissioning 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 Make sure that the 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 Before operating the boiler check that all external controls are calling for heat 6 2 Sealed Water Systems Only Flush the whole system with cold water without the pump in place Refit the pump and fill until the pressure gauge registers 2 7bar 40lbf in 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 val
40. ing to make sure a gas tight seal is made 8 5 Pilot Burner Electrode and Pilot Injector Clean the pilot burner and electrode To remove the electrode release the spring clip see diagram 8 6 When removing and replacing the pilot injector from the pilot burner take care not to damage the electrode see diagram 8 6 clean the injector by blowing through it Check that the spark gap is as shown in diagram 6 4 8 6 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 Light the boiler and carryout the functional checks as described in Section 6 Testing Flue Gases If any doubt exists that the flue products are not exhausting correctly investigate by use of a gas analyser FGA O O SECURING NUT AND P LOT SHIELD S SHAKEPROOF WASHER ELECTRODE AND LEAD UNION ASSEMBLY pilor CONNECTOR PIPE Diagram 8 3 221964D 26 n o gt QD Q ad D WING NUT Diagram 8 4 BURNER INJECTOR Diagram 8 5 isp Ri PILOT SPRING i BURNER CLIP ELECTRODE PILOT INJECTOR Diagram 8 6 9 Fault Finding 9 1 Electrical IMPORTANT Oncompletion of the Service Fault Finding task which has required the breaking and remaking of the electrical connections the earth continuity polarity short circuit
41. ing sequence is automatic as follows The fan operates The spark ignition operates The pilot solenoid opens The pilot burner lights gt neon 3 will light J x The ignition spark stops The main solenoid opens gt neon 4 will light and after a short period of time the main burner will light look through viewing window see diagram 6 3 Very cold weather may delay the operating sequence The main burner will stay alight until switched off either by the control thermostat or a remote system control To make sure that the flame supervision device is working correctly the following should be done 1 With the main burner alight turn the gas service cock Off see diagram 6 1 After a short period the main burner and pilot will go out 2 The correct working of the flame supervision device is shown by neon 4 going out within 10 seconds and the ignition starting up Neons 1 2 and 3 should stay alight 3 If the above does not happen refer to fault finding Section 9 1 4 To carry on turn the gas service cock On see diagram 6 1 When the boiler switches Off both the pilot and main burner go out The automatic lighting sequence will work again when heat is required If an external control switches the boiler off the pump will run on for a predetermined time 6 5 Testing Gas With the boiler on proceed as follows The whole of the gas installation including the meter should be insp
42. ive L blue neutral N and green and yellow earth E 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 a greater length than the current carrying conductors so that if the cable is strained the earth conductor would be the last to become disconnected 5 8 Gravity Domestic Hot Water Systems Fit the yellow link cable supplied in the fittings pack between terminal K1 and K2 see diagram 5 9 5 9 Pump Connection FULLY PUMPED The pump must be connected directly to the control box as shown in diagram 5 10 threading the cable through the cable clamp in the side of the control box PUMPED HEATING AND GRAVITY DOMESTIC HOT WATER The pump must be wired into the central heating remote controls Make sure that the supply cable and all external cables are secured and away from hot surfaces ELECTRICAL CONNECTIONS AIR ERER vate TUBES CLEAR RED 4084 REAR SECURING SCREW 2 SLACKEN but do not remove GASKET SECURING SCREW 2 Diagram 5 4 221964D 5 Boiler Installation Diagram 5 5 0 RIGHT REAR VERTICAL FAN DUCT EXTENSION Cutting MARK lengths Lefthand flue does not require cutting FLUE ELBOW Diagram 5 6 GASKET o BLANKING REAR FLUE OUT
43. left and right hand side Remove and discard the original O rings from the flanged connections and fit the new O ring supplied into recess before fitting the replacement multifunctional control After assembly test for gas soundness and purge in accordance with the current issue of BS6891 or in IE the current edition of 1 S 813 Domestic Gas Installations 10 Replacement of Parts 10 8 Solenoid diagram 10 3 Q O Remove the electrical plug from the multifunctional control Q Remove the securing screw and then the solenoid Assembly 10 9 Main Burner Remove the main burner as Section 8 3 Aa RESTRICTOR 10 10 Main Injector EXTENDED Remove the main burner as Section 8 3 PILOT PIPE SCREWS 2 Remove the main injector as Section 8 4 TUBING NUT SOLENOIDS LC Z a A PAN 8 SECURING SCREW ELECTRICAL PLUG Diagram 10 3 35 221964D 10 Replacement of Parts 10 11 Insulation diagram 10 5 Combustion Chamber Front Remove the retaining screw then the insulation Sides Slide the insulation out Rear With the side insulation removed the rear insulation can be removed and replaced 10 12 Viewing Window diagram 10 6 Remove the old self adhesive aluminium foil gasket and the old mica window Replace with a new mica window Peel off the backing paper and secure with new self adhesive aluminium foil gasket see diagram 10 6 Ensure no air bubbles are t
44. low worm 1 16 Heating System Controls The heating system should have installed a programmer and room thermostat controlling the boiler Thermostatic radiator valves may be installed however they must not be fitted in a room where the room thermostat is located 0081M 500mm Additional clearances may be required for installation SIDE OR REAR FLUE 5mm MINIMUM CLEARANCES FROM WALLS CEILING FLOOR CUPBOARD WORKTOPS AND INFLAMMABLE MATERIALS Diagram 1 3 TABLE 2 COMPARTMENT AIR VENTS VENTILATION HIGH LEVEL LOW LEVEL REQUIREMENTS VENT AREA VENT AREA cm in cm in VENTILATION FROM ROOM 198 30 198 30 OR SPACE VENTILATION FROM 99 15 99 15 OUTSIDE NOTE For further information see the current issue of the Building Regulations approved document L1 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 17 Anti theft Kits Anti theft kits are available for these appliances contact Glow worm for further information 221964D 6811 2 Flue and Ventilation NOTE Detailed recommendations for flues are given in the current issue of BS5440 Part 1 2 1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstruction other terminals and ventilation openings are shown in di
45. m 4 8 for rear flue and diagram 4 9 for side flue then cut square and remove any burrs 4 9 Air Duct Terminal and Flue Duct Assembly Locate the flue duct into the air duct terminal see diagram 4 10 Take the flue manifold from the loose items pack together with the sealant Place the sealant onto the flue manifold Fully locate the flue manifold in to the air duct terminal and flue duct assembly as shown in diagram 4 10 make sure the correct alignment of the Top s Drill two 3mm diameter holes through the air duct terminal to the flue manifold secure with the two self tapping screws supplied in the loose items pack It should now not be possible to remove the manifold 4 10 Rear Fitting Fit the self adhesive foam seal provided in the flue pack around the air duct terminal at the position shown in diagram 4 13 4 11 Side Fitting Fit the self adhesive foam seal around the air duct terminal such that when installed the seal will be within the wall see diagram 4 14 If dimension A is greater than 75mm from the wall the self adhesive foam seal can be dispensed with and the area around the flue made good in the normal way see diagram 4 14 6830 lt _LONG Na TERMINAL BOILER CENTRE EE a oo h Diagram 4 9 4616 AIR DUCT TERMINAL ASSEMBLY TOP D FLUE DUCT SEALANT AIR DUCT TERMINAL AND FLUE DUCT ASSEMBLY FLUE N MANIFOLD Diagram 4 10 221964D
46. manufacturer The expansion vessel volume depends upon the total water system volume and the initial system design pressure For any system an accurate calculation of vessel size is given in the current issue of BS5449 and BS7074 Part 1 for IE refer to the current edition of I S 813 Domestic Gas Installations Example For an initial system design pressure of 0 7bar the minimum total vessel volume required is 0 063xTotal System volume NOTE A higher initial design pressure requires a larger volume expansion vessel 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 13 Pressure Gauge 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 14 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 15 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 currentissue of BS6700 If fitting into
47. n 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 Ceramic fibre Insulation pads 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 Thermostats These contain very small amounts of xylene in the sealed phial and capillary If broken under normal circumstances the fluid does not cause a problem but in case of skin contact wash with cold water If swallowed drink plenty of water and seek medical attention Cut off Devices These contain activated charcoal and a very small amount of chlorodifluormethane in the sealed phial and capillary If broken under normal circumstances the fluid does not cause a problem If there is irritation to the eyes or skin then seek medical attention SPARE PARTS REMEMBER When replacing a part on this appliance use only spare parts that you can b
48. number on the diagram and the list will help to identify When ordering any spare parts please quote the number and the part 11 2 Ordering description from the list together with the model name and serial number If ordering from British Gas also quote the GC number of the appliance and part Key No Part No Description GC Part No 1 203374 Multifunctional control TANS 2 208040 O ring 334 592 3 205701 Injector 60FF 313 393 4 203431 Pilot burner 379 204 5 2000801236 Mica window and gasket 6 2000800478 Fan assembly 60FF 278 008 7 202626 Spark electrode and lead 313 998 8 K3580 Clip 390 983 9 800850 Thermostat control 60FF FAEEES 10 202201 Air pressure switch 313992 11 2000800400 Control knob 313917 13 202015 Fuse 334750 14 900847 Control board PCB iioi 15 800272 Thermostat cut off 313 606 221964D 38 11 Spare Parts L98S Diagram 11 1 221964D 39 Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions 221964D 40
49. on is drawn to the current issue of BS5449 and BS7593 on the use of inhibitors in central heating systems If an inhibitor is to be used contact a manufacturer or Glow worm for their recommendations as to the best product to use When installing in an existing system take special care to drain the entire system including radiators then thoroughly cleaning out before installing the boiler whether or not adding an inhibitor 3 10 Sealed Water Systems The installation should comply with the appropriate requirements of the current issue of BS4814 BS5449 BS6759 BS6798 and BS7074 Part 1 and 2 see diagram 3 5 for a suggested layout 3 11 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 221964D 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT 6455 22mm VENT 450mm MIN MIN a HEIGHT 15mm MINIMUM COLD FEED FEED AND z EXPANSION 5 z CISTERN f aol 1150mm a LL MIN y A CYLINDER T O oy HEATING There must always be a cold water path to the return connection of the boiler Bax 150mm MAX RET IF REQU
50. ot water can be provided by gravity or pumped circulation Wherever possible all materials appliances and components used shall comply with the requirements of applicable British Standards Where no British Standard exists materials and equipment should be fit for their purpose and of suitable quality and workmanship Refer to Manual Handling Operations 1992 regulations Sheet Metal Parts WARNING When installing or servicing this boiler care should be taken 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 Diagram 1 1 The Current I E E Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent person and installed in accordance with the current edition of 1 S 813 Domestic Gas Installations the current Building Regula
51. our installer or Glow worm s own Service Organisation using the telephone number given on the controls tray 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 Boiler Clearances If fixtures are positioned close to the boiler space must be left as shown in diagram 2 At least a minimum clearance of 500mm must be left in front of the boiler to allow for servicing Boilers Installed in a Compartment or Cupboard If the boiler is installed in a compartment or cupboard do not obstruct any ventilation openings Do not use the compartment or cupboard for storage 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 CONTROLS COVER 4140 DATA amp SERIAL 10264 v CONTROL THERMOSTAT S KNOB SETTING POINT GAS SERVICE COCK Shown Off Diagram 1 221964D Instructions for Use Boiler Electrical Supply WARNING This boiler must be eart
52. ram 5 1 Remove the packing piece from inside the front cover Place front cover on one side until required Fit suitable compression fittings to the required tappings on the boiler NOTE For gravity domestic hot water use 22x28mm connections on the stubs see diagram 5 2 5 2 Mounting the Boiler As necessary fit the blanking plate see diagram 5 5 Now make sure that the top swing brackets are UPRIGHT IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following operation exceeds the recommended weight for one man lift Lift the boiler into position hooking over the mounting bracket Swing the brackets over the two screws at the top Hold the swing bracket s in place whilst tightening the screw s onto it see diagram 5 3 Remove the blue and red electrical connections from the fan see diagram 5 4 Break the air pressure switch tube connections see diagram 5 4 Remove the fan assembly by removing the screws at the front slackening the screws at the rear and sliding it out see diagram 5 4 Taking care notto damage the gasket secure the flue assembly to the boiler using the previously fitted dogpoint screws noting that these are keyhole fixings see diagram 5 5 Make sure of the correct fitting of the flue to the boiler For a side outlet cut the fan duct extension to the length required see diagram 5 6 Remove any burrs and fit as diagram 5 6 Fit the fan duct extension to t
53. rapped underneath the foil Important Make sure that the mica window fully covers the opening and that the hole in the aluminium foil gasket is centred over opening 221964D 36 FRONT INSULATION 2 RETAINING SCREW REAR INSULATION Diagram 10 5 10 Replacement of Parts 10 13 Air Pressure Switch diagram 10 7 Release the control box as Section 5 6 Remove the air pressure tubes and electrical connections from the PCB release the screws and remove the switch When fitting the replacement make sure that the plastic tubes are fitted as shown in diagram 10 7 and that electrical connections are made as shown in diagrams 9 6 or 9 7 10 14 Fan diagram 5 4 Remove the electrical connections and disconnect the air tubes Remove the fan assembly securing screws at the front and slacken those at the rear and withdraw the assembly Make sure that the earth connection is remade onto the new fan assembly The polarity of the other connections is not important 37 N O MICA WINDOW p OPENING INSIDE FACE OF THE BOILER FRONT COVER PEEL OFF SELF ADHESIVE BACKING ALUMINIUM FOIL PAPER ASKET G Diagram 10 6 AIR PRESSURE CLEAR SWITCH TUBES 1 SECURING R RED AIR lt PRESSURE H ELECTRICAL SMIG CONNECTIONS CONTROL BOX Diagram 10 7 221964D 11 Spare Parts 11 1 Part Identification The key
54. t with a match Test the pilot supply and connections for gas soundness using a suitable leak detection fluid Very cold weather may delay the operating sequence The pilot rate is preset and must not be adjusted The step adjustment screw must not be touched 221964D 22 Lo ee oO vt OVERHEA RESET BUTTON CONTROL THERMOSTAT KNOB eae SERVICE SETTING ms K POINT SHOWN OFF Diagram 6 1 COVER SCREW GAS PRESSURE ADJUSTMENT SCREW MAIN BURNER PRESSURE TEST POINT MULTIFUNCTIONAL CONTROL NOTE Do not adjust any f other setting screws Diagram 6 2 6 Commissioning The pilot flame length should be as shown in diagram 6 4 Turn the control thermostat knob to O and isolate the boiler from the electrical supply Fit the combustion chamber front Reconnect the ignition lead to the PCB Stick the self adhesive arrow indicator to the data label against the rating that the boiler is going to be set to for future reference The arrow is in the loose items pack Loosen the main burner pressure test point screw and connect a suitable pressure gauge see diagram 6 2 Make sure that any remote controls are calling for heat Switch on connect the electrical supply to the boiler and heating system neon 1 will light 6 4 Testing Electrical Turn the boiler thermostat knob fully clockwise to the maximum setting which is about 82 C 180 F neon 2 will light The light
55. tions 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 1 8 813 BS5546 BS 5449 BS 7074 BS 7593 Manufacturer s instructions must not be taken as overriding statutory requirements 1 2 Data See Table 1 and diagram 1 1 All dimensions are given in millimetres except as noted The Seasonal Efficiency Domestic Boilers UK SEDBUk is 79 4 The value is 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 I 1 3 Range Rating This boiler is range rated and may be adjusted to suit individual system requirements See diagram 1 2 for the ratings and settings 221964D 1 General Data oO DATA TABLE 1 2 TOTAL DRY WEIGHT 47 5kg 105lb Including Terminal LIFT WEIGHT 42kg 93lb WATER CONTENT 2 95L 0 65gal GAS CONNECTION Re 2 in ELECTRICITY 71W RATING Internal fuse Type F1A WATER 4x22mm copper pipes from CONNECTION top of case ELECTRICITY iy SUPPLY 230V 50Hz fused 3A DATA LABEL Bottom right hand side of case Min Medium Max APPROX m h 1 69 1 85 2 0 GAS RATE ft h 60 0 65 0 71 0 1 4 B S I Certification This boiler is certificated to the
56. um operational and servicing clearances are provided Additional clearances may be required for installation If fixtures are positioned next to the boiler they should be made removable for access to pipework At least a minimum clearance of 500mm must be left in front of the boiler for servicing see diagram 1 3 1 13 Room Ventilation The boiler is room sealed and does not require the room or space containing it to have permanent air vents 1 14 Boilers in a Compartment Where the installation of the boiler will be in an unusual position special requirements are needed the current issue of BS6798 gives detailed guidance on these requirements A compartment used to enclose the boiler must be designed and constructed specifically for this purpose An existing cupboard or compartment modified for the purpose may be used 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 permanenthigh and low level ventilation must be provided The minimum ventilation areas required are given in Table 2 1 15 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 Ifin doubt seek advice from the local gas undertaking or G
57. ve should open within 0 3bar 4 3lbf in of the preset pressure Where this is not possible conduct a manual check and test Release cold water to initial system design pressure The set pointer on the pressure gauge should be set to 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 all naked lights and cigarettes are out Identify the controls by reference to diagram 6 1 Check that the boiler is isolated from the electrical supply Makes sure that the control thermostat is turned to O the Off position Turn the gas service cock On see diagram 6 1 Test the pilot supply tube and its connections for gas soundness as follows Disconnect the ignition lead from the PCB see diagram 5 9 Remove the combustion chamber front see diagram 6 3 WARNING The fan operates on mains voltage terminals will become live Turn the electrical supply on and check that all remote controls are calling for heat Check that the pump is circulating water through the system To complete the test it is necessary to operate the boiler without its case but UNDER ALL OTHER CIRCUMSTANCES the case must be correctly fitted and sealed Turn the control thermostat knob fully clockwise and the fan will work NOTE There will be no sparks at the pilot Take care and light the pilo
Download Pdf Manuals
Related Search