Glow-worm Hideaway 100C FF, Hideaway 115C FF Instructions For Use Installation And Servicing

0020003579A.08.04

Instructions for Use

Installation and Servicing

To be left with the user

Hideaway

100C FF

G.C. No. 41-047-42

Hideaway

115C FF

G.C. No. 41-047-43

Chimney

Fanned Flue Boiler

Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT

www.glow-worm.co.uk

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 as soon as possible your guarantee registration return
literature, supplied in the document envelope.

If your guarantee registration return literature is missing you can obtain a copy or record your registration
by telephoning the Glow-worm Customer Service number 01773 828100.

For customer service call:

[phone]

Technical helpline: [phone]

For General and Sales enquiries:

Tel. [phone]

Fax: [phone]

To register your Glow-worm appliance call:

0020003579A

0800 073 2142

2

Contents

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.

CONTENTS DESCRIPTION SECTION PAGE No.

Important Information 4

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

Draining and Filling 5
Appliance Introduction 5
Appliance Safety Devices 5
Maintenance and Servicing 6
Lighting the Boiler 7

General Data 1 8
Water Systems 2 12
Flue and Ventilation 3 13
Installation 4 15
Electrical Wiring 5 20
Commissioning 6 21
Instructions to the User 7 23

SERVICING

INSTRUCTIONS

Servicing 8 23
Fault Finding 9 26
Replacement of Parts 10 29
Spare Parts 11 31

3

0020003579A

Important Information

WARNINGS

Gas Leak or Fault

Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.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.

Sheet Metal Parts

This boiler contains metal parts (components) and care should be taken when handling and cleaning,

Under no circumstances must the User interfere with or adjust sealed parts.

with particular regard to edges.

Sealed Components

Gas safety (Installation and use) Regulations

In your interests and that of gas safety, it is the law that ALL gas
appliances are installed and serviced by a competent person
in accordance with the above regulations.

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. The
requirements are: The installation of this boiler must be
carried out by a competent person in accordance with the
current rules in force in the countries of destination at the
time of installation. Manufacture's instructions supplied.
Manufacture's instructions must not be taken as overriding
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 the 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.

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 to the eyes or severe irritation to the
skin seek medical attention.
The insulation is composed of non-combustible material.

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.

All external wiring between the appliance and the electrical
supply and earthing requirements shall comply with the current
IEE Regulations.

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
than 0.75mm2 (24/0.20mm).

o

C insulated cable, not less

Manual Handling Guidance

During the appliance installation it will be necessary to employ
caution and assistance whilst lifting as the appliance exceeds
the recommended weight for a one man lift.

In certain situations it may be required to use a mechanical
handling aid.

Take care to avoid trip hazards, slippery or wet surfaces.

Control of Substances Hazardous to Health

The adhesives and sealants used in this appliance are cured
and give no known hazard in this state.

INSULATION PADS/CERAMIC FIBRE

These can cause irritation to skin, eyes and the respiratory
tract.

0020003579A

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.

4

Important Information

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.

Air in the heating system

Persistent air in the heating system may indicate leaks in the
system or corrosion taking place. Call your Installation/Servicing
company.

Boilers Installed in a Compartment

If the boiler is fitted in a compartment, cupboard etc., do not
obstruct the purpose built compartment vents or the grill on the
boiler.

Do not use the compartment for storage purposes.

Draining and Filling

Draining and filling

Caution: The boiler must only be drained and filled by a
competent person.

If the boiler is to be out of use for any period of time during severe
weather conditions we recommend the whole system including
the boiler, be drained off to avoid the risk of freezing up. If an
immersion heater is fitted to the hot water cylinder make sure it
is switched off.

Protection Against Freezing

In this boiler 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
below 5oC. The boiler will switch off again when the temperature
of the water in the boiler reaches about 13oC. 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.

If the boiler is to be out of use for any 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.
If an immersion heater is fitted to the hot water cylinder make
sure it is switched off.

WARNING: Do not operate the boiler without water.

If in doubt, consult your servicing company.

Appliance Introduction

Introduction

The Glow-worm Hideaway C FF series are fanned flue boilers
with a chimney flue adapter. They provide heating and if
required, an indirect domestic hot water supply.

The boiler is of the I
(G20) as distributed in the United Kingdom and Ireland and
cannot be used on any other gas.

The boiler is automatic in operation, having only one user
control, the boiler temperature control.

category for use only with Natural Gas

2H

Appliance Safety Devices

Air flow rate safety device

If the flue is obstructed the built in safety system will turn the
boiler OFF. The boiler will be ready to operate when the fault has
been cleared.

The installation of this boiler must be carried out by a competent
person in accordance with the rules in force in the countries of
destination.

Manufacturer’s instructions must not be taken as overriding
statutory requirements.

These instructions should be carefully followed for the safe and
economical use of your boiler.

NOTE: The boiler serial number is marked on the data label
attached to the heat shield under the control box. The
'Instructions for Use' section describes how to safely use the
boiler.

Electrical supply failure

The boiler will not operate without an electrical supply. Normal
operation of the boiler should resume when the electrical supply
is restored.

Reset any central heating system controls, to resume normal
operation.

If the boiler does not resume normal operation it is advisable to
consult your installation / servicing company.

5

0020003579A

Maintenance and Servicing

Cleaning

WARNING: This appliance contains metal parts (components)

and care should be taken when handling and cleaning with
particular regard to edges of sheet metal parts to avoid any
possibility of personal injury.

The boiler casing can be cleaned with a damp cloth, followed by
a dry cloth to polish.

Do not use abrasive or solvent cleaners.

Maintenance and Servicing

To ensure the continued efficient and safe operation of the
appliance 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,
refer to guarantee registration with this literature.

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.

Servicing/maintenance should be carried out by a competent
person in accordance with the rules in force in the countries of
destination.

To obtain service, please call your installer or (Glow-worm’s
own service organisation) using the telephone number on the
inside front cover of this literature.

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
benchmark Logbook. You can check your installer is CORGI
registered by calling CORGI direct on: 01256 372300.

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

If a part is required contact (Glow-worm’s own service
organisation) using the telephone number on the inside front
cover of this booklet.

Please quote the name of the appliance, this information will be
on the name badge on the front of the appliance.

If in doubt seek advice from the local gas company or
(Glow-worm’s own service organisation) using the telephone
number on the inside front cover of this booklet.

Boiler casing

CAUTION: Do not remove or adjust the casing in any way, as

incorrect fitting may result in faulty operation. If in doubt, consult
your installation/service company.

0020003579A

6

Instructions for Use

To Turn the Appliance On

Do not operate the boiler without water.

Turn the electrical supply on to the boiler and check that all
remote controls are calling for heat. The fan will operate.

It should be noted that this is a fanned flue appliance and fan
operation may be heard.

Turn the boiler temperature control clockwise to any position
between “0” and "Max", see diagram 1.

"Max" is approximately 82°C (180°F).

The boiler lighting operation is now automatic as follows:

The fan operates and after a short period of time, the spark
ignition operates, the solenoid opens, then the burner will light
shown by the burner ON indicator (green) on the control panel
lighting up.

The burner will remain alight until switched off by the control
thermostat or any remote control.

NOTE: If the boiler is turned OFF at the boiler temperature
control, wait at least 30 seconds before switching on again.

When the boiler switches off, the burner will go out.

The automatic lighting sequence will operate again when heat
is required.

If the reset/standby indicator lights, turn the boiler temperature
control to "0" (off), wait 30 seconds, then repeat the lighting
instructions.

BOILER
TEMPERATURE
CONTROL

10132

To Turn the Appliance Off

For short periods, turn the boiler temperature control fully anti­clockwise to “0” (off), the reset/standby indicator will be on.

To relight, turn the boiler temperature control to any position
between “0” and “MAX”.

For longer periods, turn the boiler temperature control fully anti­clockwise to “0” (off) and switch off the electrical supply to the
boiler.

To relight follow the lighting sequence given above.

"OFF"
POSITION

RESET
/ STANDBY
INDICATOR

"BURNER ON"
INDICATOR

Diagram 1

7

0020003579A

1 General Data

10135

32

474

C

L

145

*

MAX

900

MIN

294

860

350

GENERAL DIMENSIONS - given in millimetres

558

555

300

442

NOTE:
The boiler casing can be set at

80

two heights, MAX. and MIN.

WATER CONNECTIONS
Rc1 reduced with
DISTRIBUTOR TUBE to

3

Rc

3

/

(

/

4

in. B.S.P.T.)

4

(pumped return)

GAS CONNECTION

1

1

/

3

Rc

/

(

2

2

in. B.S.P.T.)

WATER CONNECTIONS

Rc1 (1in. B.S.P.T.)

INSIDE DIAMETER OF

*

ADAPTER FOR 125mm (5in)
NOMINAL DIAMETER FLUE
TO BS567

Diagram 1.1

Important Notice

This boiler is for use only 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.

Wherever possible, all materials, appliances and components
to be 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.

1.1 Technical Data

Refer to diagrams 1.1, 1.2, and 1.3.

All dimensions are given in millimetres (except as noted)

Approximate weight of complete boiler and packaging:

143kg (315lb)

Water content : 11.7 litre (2.57 gallons)

Gas connection : Rc

Water connection : Rc1 (1in BSPT)

Electrical supply : 230V~50Hz, fused 3A

Burner : Aeromatic

The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is "D", 100C FF = 78.9% 115C FF = 78.7%.

The value is used in the 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

/2 (1/2in BSPT)

.

1.3 Statutory Requirements

The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.

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
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
I.S.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.S.813, BS5546, BS 5449, BS 7074, BS 7593.

Manufacturer’s instructions must not be taken as overriding
statutory requirements.

1.2 Range Rating

See diagrams 1.2 and 1.3.

0020003579A

8

1 General Data

1.4 B.S.I Certification

This boiler is certificated by B.S.I., for safety and performance.
It is, therefore, important that no alteration is made to the boiler
unless agreed, in writing, by Glow-worm

Any alteration not approved by Glow-worm, could invalidate the
B.S.I. certification, boiler warranty and could 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 I.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

WARNING: This boiler must be earthed.

The electrical installation must be carried out by a competent
person. All external components shall be of the approved type

and shall be connected in accordance with the current issue of
BS7671 and any local regulations which apply.

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 I.S.813 "Domestic Gas
Installations".

Connection of the boiler and any system controls to the mains
supply through an unswitched shuttered socket outlet and 3A
fused 3 pin plug, both to the current issue of BS1363.
Alternatively, a 3A fused double pole isolating switch may be
used, having a minimum double pole contact separation of
3mm, serving only the boiler and system controls.

2

Heat resistant cable of at least 0.75mm
current issue of BS6500 Table 16, must be used for all
connections within the boiler casing, to the control box, pump
etc.

(24/0.20mm), to the

10144

Diagram 1.2

10147

Diagram 1.3

9

0020003579A

1 General Data

1.7 Condensate Drain

A plastic drain pipe may need to be fitted to allow discharge of
condensate to a drain.

Condensate should, if possible, be discharged into the internal
household draining system. If this is not practical, discharge can
be made externally into the household drainage system or a
purpose designed soak away, see section 4.11 for more details.

1.8 Boiler Location

This boiler is not suitable for outside installation.

The boiler must not be installed in a room used or intended to
be used as sleeping accommodation or a room containing a
bath or shower.

In GB this is the current I.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 casing can be fitted at two heights. Refer to
diagram 1.4.

The boiler is assembled at the factory with the control box and
heat shield fitted in the lower position.

The boiler must stand on a level floor, conforming with local
authority requirements and building regulations.
The base temperature is within the requirements of the current
issue of BS5258. The boiler may stand on a wooden floor but
a metal base plate is required to protect plastic tiles and similar
floor coverings.

Suitable installation clearance needs to be available at the
sides of the boiler to facilitate direct connection of pipework and
making good around the flue assembly. The actual clearance
required will vary with site conditions.

When the boiler is to be installed level with work surfaces and
the like, minimum clearances should be provided as shown in
diagram 1.5. Work tops which overhang the cupboard sides,
almost in contact with the casing top, require a larger minimum
air gap. Flush sided fixtures require the same overall minimum
space but can have a reduced air gap on one side.

Boilers to be installed under work tops or fixtures, should be
positioned to provide minimum clearances as shown in diagram

1.6. To facilitate minimum clearances it may be necessary to
modify kitchen units and fixtures.

Combustible material must be a minimum of 25mm (1in) away
from the flue components, see diagram 1.6.

A front access clearance for servicing of 700mm, should be
provided.

The boiler can be installed within a cupboard, refer to minimum
ventilation and clearances as shown in diagram 1.7

If the boiler is to be installed in a cupboard or compartment,
make sure that nothing will obstruct the openings/vents in the
compartment.

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 features of cupboard or compartment
design are given in the current issue of BS6798.

Where the installation of the boiler will be in an unusual location,
special procedures are necessary the current issue of BS6798
gives detailed guidance on this aspect.

To
floor
level

MAX.900
MIN. 860

MAX.

MIN.

FLOOR LEVEL

BOILER CASING HEIGHT(S)

WORKTOP

10 10

494 MIN.

BOILER

CUPBOARDS

MINIMUM CLEARANCES
LEVEL WITH WORKTOP

WORKTOP
OR FIXTURE

25

10

CUPBOARD

MINIMUM CLEARANCES
UNDER WORKTOP, FIXTURES

9922

BOILER
CASING
ALTERNATIVE
HEIGHT
POSITIONS

Diagram 1.4

9923

494 MIN.

5

BOILER

Diagram 1.5

10

9924

10

CUPBOARD

Diagram 1.6

0020003579A

10

1 General Data

1.9 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.

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.

406cm2 FREE AREA

10mm

FOR VENTILATION

10mm

DOOR

CUPBOARD

CUPBOARD

406cm2 FREE AREA
FOR VENTILATION

IMPORTANT

A CLEARANCE OF 10mm IS REQUIRED
BETWEEN THE FRONT OF THE APPLIANCE
AND THE FITTED DOOR.

11601

10mm

2 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 I.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 I.S.813
"Domestic Gas Installations" and the current Building Regulations
must be followed.

It is recommended that plastic pipes for primary pipework
should not be used for this boiler.

THE VENTILATION SLOTS ON THE FRONT
OF THE APPLIANCE MUST BE KEPT CLEAR.

THE FREE AREA FOR VENTILATION MUST
NOT BE REDUCED IF A GRILLE IS FITTED.

CUPBOARD MINIMUM
VENTILATION & CLEARANCES

Diagram 1.7

0869

2.1 Water Pressure Head

The boiler shall only be connected to a cistern water supply with
a minimum head of 1 metre (3ft3in) and a maximum head of
27metres (90ft) which has an open vent in the system.

11

Diagram 2.1

0020003579A

2 Water Systems

The working pressure must be within the range 0.1bar to 2.7bar
(1.3 to 39lbftin

The boiler MUST NOT be connected to a sealed water system.

2

).

2.2 Inhibitor

Attention 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 in the system, contact should be
made with the inhibitor manufacturers so that they can
recommend their most suitable product.

When using in an existing system take special care to drain the
entire system, including the radiators, then thoroughly clean out
before fitting the boiler whether or not adding an inhibitor.

2.3 Gravity Domestic and Pumped Heating

It is recommended that a cylinder thermostat is used to prevent
the stored water temperature becoming unnecessarily high
when the central heating pump is off.

The domestic primary flow and return must be 28mm o.d. The
installation must comply with the current issue of BS5546 and
BS6700, see diagram 2.1.

If the above conditions cannot be met, it is suggested that a fully
pumped system be used.

2.4 Pumped Heating and Hot Water

Where a single flow and return is taken from the boiler, a
minimum static head of 1 metre (3ft3in) must be provided
between the water line of the feed tank and the centre of the
waterway, see diagram 2.2.

2.5 Circulation Pump

Normally the pump should be set to give a temperature difference

o

of 11

C (20oF) across the boiler. At the appropriate pumped flow
rate the pressure loss through the boiler can be found from the
graph, diagram 2.3.

Use a pump with integral valves or fit isolating valves as close
to the pump as possible.

2.6. Cylinder

For all systems supplying domestic hot water the cylinder must
be indirect.

2.7 Safety Valve

A safety valve need not be fitted to an open vented system.

FULLY PUMPED SYSTEM
(DIAGRAMMATIC)

FLOW RATE (GALLON/MINUTE)
012345678 109

1.2

1.0

0.8

0.6

0.4

0.2

WATER PRESSURE LOSS

(metre HEAD OF WATER)

0

10

0

FLOW RATE (LITRES/MINUTE)

20 30

Diagram 2.2

40 50

Diagram 2.3

0870

1370

40

30

20

10

WATER PRESSURE LOSS

(INCHES HEAD OF WATER)

0

2.8 Draining Tap

A draining tap must be provided at the lowest points of the
system which will allow the draining of the entire system,
including the boiler and hot water cylinder.

Draining taps should be to the current issue of BS2879.

2.9 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 20oC
between flow and return with the thermostatic valves closed.

0020003579A

12

3 Flue and Ventilation

Important Notes

The flue must be installed in accordance with the rules in force
in the countries of destination.

The flue must be in accordance with the current issue of
BS5440 Part 1.

The Chimney Flue Adapter Kit (Part No. 2000461944) socket is
designed to take flue pipes to the current issue of BS567. If a
flue pipe to BS715 is to be used, an adapter must be fitted to the
boiler flue socket.

The flue must be at least the equivalent to 1m vertical.

The maximum flue length must not exceed 15m vertical.

If the flue exceeds the following:

100CFF - 10m, 115CFF - 11m

the condensate drain on the chimney flue adapter must be
connected and we would recommend that one of the following
flue liners should be used or an equivalent specification:

Ritevent - Chimflex LW or SB

Selkirk - Selflex TS or TSE

An existing liner must be changed if there is any doubt that it will
not operate safely throughout the life of any new appliance.

A drain point is incorporated on the chimney flue adapter to
which a drain pipe can be connected, refer to section 4.10.

3.1 Flue Guidelines

The flue should be kept as short as possible. Horizontal or very
shallow runs of the flue should be avoided as they encourage
local cooling.

Always choose a flue route which will cause the least cooling of
the flue.

90° elbows should not be used.

SEALING AND
CLAMPING
PLATE

AIR
SPACE

The existing flue may not be completely sound. Therefore, to
prevent the possibility of leakage, additional sealing MUST be
carried out between the base of the chimney and the flue liner.

The end of the flue liner at the chimney top must be adequately
sealed and clamped, using proprietary fittings suitable for the
flue liner used, see diagram 3.1.

The flue should, preferably, end above ridge height but at the
least above the eaves of a pitched roof. Use a certificated
terminal.

If the flue is pass through or near any combustible material it
should be installed in accordance with the current issue of
BS5440 Part 1.3. If in doubt seek advice from the local gas
undertaking or Glow-worm

3.2 Chimney

An existing brick chimney must be thoroughly swept and all
debris cleared away before lining.

Remove any damper or register plate. Alternatively it may be
locked in the fully open position.

A flexible flue liner is preferred but a rigid liner may be used, with
connection to the boiler flue socket made with a short vertical
piece of flexible liner, see diagram 3.2.

The sealing plate also prevents debris falling and gives the flue
better insulation, reducing the possibility of condensation, see
diagram 3.1.

A chimney can be lined with a moisture resistant lining, such as
salt glazed pipe, of an appropriate diameter as specified in the
Building Regulations.

In the case of a salt glazed flue, it is recommended that a short
vertical length of flue pipe be connected in such a manner that
any condensation from the flue is not retained. Fix and seal it
to the boiler flue socket and make good with an approved seal.
It is also recommended that a permanent drain be fitted to the
boiler.

If the flue is constructed from permeable material then it is

9914

strongly recommended that a metallic flue liner is installed.

If a flue and false chimney breast are to be constructed all
openings for pipework to upper floors etc. must be sealed.

If a specially built compartment is constructed for the boiler, it
must conform to the requirements of the current issue of
BS5440 Part 1 and BS5871.

Check the system efficiency before installing the boiler.

150mm (6in) plug of Mineral Wool or similar

SEALING

PLATE

CHIMNEY
FLUE
ADAPTER

Diagram 3.1

13

FLEXIBLE
LINER

BOILER

RIGID
FLUE
LINER

APPROVED
SEAL

CHIMNEY
FLUE
ADAPTER

Diagram 3.2

0020003579A

9915

3 Flue & Ventilation

3.3 Timber Frame Buildings

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

3.4 Ventilation for Boiler Installed in a Room
or Space

If the boiler is to be installed in a room or space a purpose
designed permanent ventilation opening, to supply air for
combustion, must be provided on an outside wall to external air,
refer to the current issue of BS5440 Part 2 for details.

The opening may be directly into the room or the space
containing the boiler, or an outside wall of an adjacent room or
space which has an internal permanent air vent, of the same
size, into the room or space containing the boiler.

Do not ventilate through a bedroom, bedsitting room, private
garage or a room containing a bath or shower.

When the boiler is installed in a room or internal space already
containing other fuel burning appliances then the air supply of
such appliances must be taken into account.

The ventilation opening areas are given in “Air Vent Table ”. The
figures quoted refer to the minimum acceptable effective area.

3.5 Ventilation for Boilers Installed in a
Compartment

When the boiler is fitted in a compartment, high and low level
purpose designed, permanent openings must be provided to
supply air for combustion and compartment ventilation.

The air vents must have minimum areas, see “Compartment Air
Vent table". The figures quoted refer to the minimum acceptable
effective area.

Both the high and low level openings must communicate with
the same room, or must both be on the same wall to outside air.

If air vent grilles are fitted to a cavity wall, the opening through
the wall must be ducted.

Where ventilation air to a compartment is taken from a room or
space, then the room or space must be fitted with a ventilation
opening as specified in “Air Vent Table”.

For information regarding compartment requirements refer to
the appropriate section of the current issue of BS6798.

FOR ROOM SPACE INSTALLATIONS

100C FF

115C FF

COMPARTMENT AIR VENT TABLE

COMPARTMENT
VENTILATION
REQUIREMENTS

VENTILATION
FROM ROOM
OR SPACE

FROM
OUTSIDE

AIR VENT TABLE

EFFECTIVE AREA OF VENT

126cm

152cm

2

2

20in

24in

2

2

HIGH LEVEL LOW LEVEL

VENT AREA VENT AREA

100C FF 323cm250in2646cm2100in

115C FF 374cm258in2747cm2116in

100C FF 162cm225in2323cm250in

115C FF 187cm229in2374cm258in

2

2

2

2

3.6 Ventilation for Boilers installed in a
Cupboard

For minimum ventilation and clearances for cupboard installation
refer to section 1.8 and diagram 1.7.

3.7 Extract Fans

If an extract fan is fitted in the premises, there is a possibility that
if adequate inlet openings are not provided, spillage of the
products from the boiler could occur.

When openings are fitted in accordance with the current issue
of BS5440 Part 2 and this section, extract fans should not cause
down draught, but where such fan installations are found, a
spillage test must be carried out in accordance with the current
issue of BS5440 Part 1 and any corrective work done.

0020003579A

14

4 Installation

General Installation Notes

The appliance pack contains :-

Boiler.

Casing panels, packed separately.

Loose items fittings pack, see list in pack.

The flue adapter with flue extension is supplied separately.

Before installation of the boiler make sure that the location
selected is in accordance with the requirements of Section 1.7.

4.1 Unpacking

The boiler casing panels are packed separately within the main
carton and are designed to enable gas and water connections
to be made before fitting the casing panels.

The casing brackets, flue restrictor, distributor tube and other
loose items, are in the fittings pack.

IMPORTANT. With regards to the Manual Handling Operations,
1992 Regulations, the following operation exceeds the
recommended weight for one man lift.

4.2 Water Connections - Gravity Domestic and
Pumped Heating

Fit suitable fittings into the boiler tappings, see diagram 4.1.
Make sure that all pipes are taken backwards and will clear the
casings, see diagram 1.1.

NOTE: It is recommended that plastic pipes for primary
pipework should not be used for this boiler.

Heating flow: Any one of the two upper connections may be
used.

Domestic flow: Any one of the remaining upper connections
may be used.

Heating return: The water distributor tube must be fitted into
either of the front lower connections on all installations, see
diagram 4.2. This tube is packed in the fittings pack.

Domestic return: Any one of the remaining lower connections
may be used for the gravity domestic hot water return.

Fit plugs into any unused boiler tappings.

4.3 Water Connections - Fully Pumped
Systems

Fit suitable fittings into the boiler tappings as required, see
diagram 4.3. Make sure that all pipes are taken backwards and
will clear the casings, see diagram 1.1.

NOTE: It is recommended that plastic pipes for primary
pipework should not be used for this boiler.

It is important that all connections are made as shown in
diagram 4.3.

Fit the water distributor tube into the return connection, see
diagram 4.2. This tube is packed in the fittings pack.

Fit plugs into any unused boiler tappings.

9859

GRAVITY
DOMESTIC
RETURN TO
ANY OF THE
3 REMAINING
LOWER
CONNECTIONS

ALTERNATIVE
HEATING RETURN
With distributor
tube (not shown)

WATER CONNECTIONS - GRAVITY
DOMESTIC, PUMPED HEATING

UPPER MARKER must lie
between the two outer
NOTCHES

DISTRIBUTOR
TUBE
MUST BE IN
PUMPED
RETURN

UPPER

CONNECTION

MARKER

DISTRIBUTOR TUBE

ALTERNATIVE
FLOW
POSITIONS
(must be
adjacent to
THERMOSTAT
PHIAL
POCKET)

ALTERNATIVE
HEATING OR
DOMESTIC
HOT WATER
FLOW
(Thermistor
phial & pocket
must be
adjacent to
heating flow
connection)

Diagram 4.1

1277

Diagram 4.2

9859

4.4 Thermistor Pocket

Fit the thermistor phial pocket supplied, in the fittings pack, into
the front tapping adjacent to the heating flow connection.
Having chosen the flow connection and plugged the alternative
connection.

Carefully unwind the thermistor capillary, insert phial fully into
the pocket and secure with grommet moulded to the cable.

WATER CONNECTIONS FULLY
PUMPED SYSTEMS

15

ALTERNATIVE
RETURN
POSITIONS
With distributor
tube (not shown)

Diagram 4.3

0020003579A

4 Installation

4.5 Pipework

It is essential that any pipework or fittings do not project
more than shown in diagram 4.4.

Do not route any pipework, water or gas, across the front
of the combustion chamber cover.

The gas pipework must be along the left hand side of the
boiler.

PIPEWORK CASING
CLEARANCES

Diagram 4.4

4.6 Casing Brackets

Fit the two upper and two front casing brackets shown in
diagram 4.6, using the No.8 screws provided.

NOTE: The screws will already be fitted.

Push the captive nuts, supplied loose, on to the casing brackets
as shown in diagram 4.5.

9860

SIDE CASING
(R.H.SHOWN)

SPRING
CLIP

IN-FILL
PANEL

12082

UPPER CASING
BRACKET

No.8
SCREW
(4)

CAPTIVE
NUT

CAPTIVE

No.8
SCREW
(4)

FRONT
CASING

NUT

BRACKET

CASING BRACKETS FITTING

Diagram 4.5

9858

UPPER VIEW

SIDE CASING
(R.H. SHOWN)

IN-FILL
PANEL

PLASTIC
PEG

SPRING
CLIP

LOWER VIEW

PLASTIC
PEG

Diagram 4.6

0020003579A

16

4 Installation

4.7 Side In-fill Panel (if required)

A side in-fill panel is supplied with the boiler, which can be fitted
at the rear of the left or right hand side casing but can be
discarded if the water connections are made on both sides of
the boiler or if the boiler is screened by fixtures. The in-fill panel
will usually be fitted on the side where there no pipework
connections.

Insert the push fit plastic location peg, supplied, through the in­fill panel and side casing holes and secure with the spring clips,
see diagram 4.6.

NOTE

The boiler is assembled at the factory with the control box and
heat shield fitted in the lower casing height position.

4.8 Side Casings

Fit the side casings by locating their lugs into the appropriate
slot in the boiler plinth, see diagram 4.7, depending on the
required height, there are two options, see section 1.8.

Secure the casing sides to the front and rear upper casing
brackets with self-tapping screws supplied, see diagrams 4.7
and 4.8.

12081

FRONT
CASING
BRACKET

MAX.

MIN.

SIDE
CASING
(R.H.)

LOCATING
SLOTS

No. 8
SCREW
(4)

9863

SCREW

"LOW"
position

"HIGH"
position

SIDE CASING
(R.H. SHOWN)

UPPER
CASING
BRACKET

Diagram 4.8

WING NUT

0886

BOILER
PLINTH

SIDE CASINGS FITTING

Diagram 4.7

17

"LOW"
position

"HIGH"
position

SELF
TAPPING
SCREWS
(3)

(3) SELF
TAPPING
SCREWS
(for height
adjustment
only)

CONTROL BOX
SUPPORT
BRACKET

Diagram 4.9

0020003579A

4 Installation

4.9 Flue / Boiler Connection

Remove the three self-tapping screws from the lower part of the
control box support bracket, see diagram 4.9.

Undo the wing nut that secures the top of the heat shield and
carefully hinge down control box and heat shield, see diagram

4.9.

Release the three toggle latches that secure the fan access
door and remove, see diagram 4.10.

Remove the electrical connections from the fan by pulling the
insulation boots only and disconnect the two air pressure tubes
from the fan taking note of their positions, see diagram 4.11.

Remove the fan assembly from the flue hood by removing the
securing screw, pull forward and lift up to release the 3 hooked
securing lugs underneath the fan, see diagrams 4.11 and 4.12.

From the Chimney Flue Adapter Kit take the flue spigot, the
gasket is supplied in the fittings pack.

Connect the flue spigot and gasket to the top flue outlet of the
boiler using the self tapping screws provided, see diagram 4.13.

From the Chimney Flue Adapter Kit, take the chimney flue
adapter and remove restrictor securing screw, select and fit
appropriate restrictor ­100CFF: marked 'D'
115CFF: marked 'E'
then secure in place with the previously removed screw. To

connect a condensate drain, remove plastic end stop by
depressing the collet.

Slide the Chimney Flue Adapter into the flue spigot until it
engages in the bayonet connection, then twist clockwise to lock,
see diagram 4.13.

Rest the flue duct extension on the support bracket and engage
into the chimney flue adapter, see diagram 4.14. Refit fan
ensuring it is engaged into the flue duct extension and the
securing lugs are located correctly into the flue hood, secure
with fan securing screw. Replace electrical connections and air
pressure tubes.

The polarity of the electrical connections is not important.

Make sure that the air pressure tubes are fitted as before, see
diagram 4.11 and that the fan duct engages fully into the flue
duct extension piece.

IMPORTANT. With regards to the Manual Handling Operations,
1992 Regulations, the following operation exceeds the
recommended weight for one man lift.

Place the boiler in position taking care not to damage the casing
panels.

FAN ACCESS
DOOR

FAN ELECTRICAL
CONNECTIONS

10266

AIR
PRESSURE
TUBE (RED)

FAN
SECURING
SCREW

REAR AIR PRESSURE
SWITCH TUBE (RED)

12103

TOGGLE LATCHES

TOGGLE LATCHES

Diagram 4.10

FRONT AIR
PRESSURE SWITCH
TUBE (CLEAR)

Diagram 4.11

Flue Connection

NOTE: Fix and seal the flue to the hood of the chimney flue
adapter in accordance with normal practice.

The flue should be 125mm (5in) nominal diameter, refer to
section 3.

0020003579A

12084

SECURING
LUGS (3 OFF)

Diagram 4.12

18

4 Installation

4.10 Water and Gas connections

Replace fan access door, heat shield and control box.

NOTE: When replacing the fan access door make sure the lip
at the top of door fits into and behind the slotted bracket located
at the top of the boiler.

As there are two casing height options, the control box height
and the heat shield may have to be adjusted to suit your
requirements.

Complete the water connections to the boiler.

Fill, vent and flush the system.

Check for any water leaks and put right.

Make the gas connection to the service cock, at the lower left
hand side of the boiler, see diagram 1.1.

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".

4.11 Condensate Drain Connection
(If Applicable)

With reference to Section 3, should your flue be greater than the
"Dry" flue length stated, then a condensation drain should be
fitted.

To use the condensate drain connection on the chimney flue
adapter, remove the end stop, see diagram 4.13. A 22mm
plastic overflow pipe should be used to fit on to the drain
connection and discharge to a drain. The drain pipe should have
a fall of at least 2.5° away from the boiler and should incorporate
a 'U' trap.

Condensate should, if possible be discharged into the household
internal drainage system. If this is not practicable, discharge
can be allowed into the external household drains or by a
purpose designed soak away.

It is recommended that any external condensate drain is insulated
and also preferably of 32mm diameter, to prevent freezing in
adverse weather conditions.

4.12 Top Casing

Refer to diagram 4.15.

Fit two plastic pegs, one on each side, in the holes on the top
casing. The plastic pegs are a tight fit and are best pushed home
with a flat faced tool.

Secure front of top casing with the two screws provided.

CHIMNEY
FLUE
ADAPTER

FLUE DUCT
EXTENSION

SUPPORT
BRACKET

11341

RESTRICTOR
SECURING SCREW

END STOP

CHIMNEY
FLUE
ADAPTER

FLUE
SPIGOT

RESTRICTOR

SECURING
SCREW

GASKET

Diagram 4.13

11339

TOP
CASING

FLUE HOOD

SCREW (2)

Diagram 4.14

9865

PLASTIC
PEG (2)

Diagram 4.15

19

0020003579A

5 Electrical Wiring

SECURING
SCREWS

TERMINAL
BLOCK

BOILER
TEMPERATURE
CONTROL

5.1 Control Box Access

Remove control box cover by undoing the four securing screws
(two on control box, two on the heat shield) and lift off, see
diagram 5.1.

5.2 Electrical Connections

WARNING: This boiler must be earthed.

Take care not to damage any internal wiring.

Using heat resistant (85

0.2mm) and of a suitable length, route as shown in diagram 5.3.
Thread through the grommet at the bottom rear of the control
box, through the cable clamp and connect to appropriate
terminals. Tighten cable clamp screws, see diagram 5.2.

Standard colours are, brown - live (L), blue - neutral (N) and
green/yellow - earth

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.

o

C) cable of at least 0.75mm2 (24/

.

CONTROL BOX
COVER

TERMINAL BLOCK

CONTROL

CONNECTIONS

BOX

CABLE
CLAMP
SCREW

MAINS INLET
CONNECTOR

HEAT RESISTANT
CABLE

12417

bk

Diagram 5.1

12086

CABLE
CLAMP

Diagram 5.2

12085

5.3 Pump Connection

The pump must be connected to the external controls.

5.4 Testing - Electrical

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 of the controls scheme used with the boiler.

Replace the control box cover.

0020003579A

CABLE
CLIPS

CABLE
CLIPS

Diagram 5.3

20

6 Commissioning

IMPORTANT NOTE: The WARNING NOTICE attached to
the front casing must only be removed by the user.

Please ensure the “Benchmark” logbook is completed and left
with the user, and the magnetic lighting instruction label is
placed on the surface of the boiler casing.

6.1 All Systems

Commissioning should be carried out by a competent person
in accordance with the current issue of BS6798.

WARNING: Do not operate the boiler without water.

UNDER ALL CIRCUMSTANCES the case must be correctly

fitted and sealed, unless fault finding.

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.

6.2 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 extinguished.

Refer to ‘Instructions for Use’ and identify the controls.

Check that the boiler is isolated from the electrical supply.

Turn the gas service cock “On” , see diagram 6.1.

Purge in accordance with the current issue of BS6891.

WARNING: The multifunctional control and fan operate on
mains voltage, terminals will become live.

If programmer control is fitted, make sure it is in the ON mode.

Make sure that any remote controls are calling for heat.

Turn the boiler temperature control clockwise to “Max”.

The ignition system will operate to light the boiler. After a pre­set time if ignition has not taken place the boiler will shutdown.

To re-start the lighting sequence, turn the boiler temperature
control to “O”, then fully clockwise to “Max”.

"Max" is approximately 82°C (180°F).

After the burner has lit, the “Burner on” indicator on the 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 6.1.

Switch on the electrical supply to the boiler.

WARNING: The multifunctional control and fan operate on
mains voltage, terminals will become live.

6.3 Testing - Electrical

Turn the boiler temperature control knob fully clockwise to the
maximum setting, which is approx. 82

The lighting sequence is 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 stay alight until switched off, either by the
temperature control or remote system control.

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 6.1.

After a short period the burner will go out but the fan will
continue to run.

The correct working of the flame supervision device is shown by

o

C (180oF).

12166

C

BOILER COMPONENTS

12030

A

B

H

A

F

G

A CONTROL BOX

E

B PHIAL POCKET
C GAS SERVICE COCK
D "BURNER ON" INDICATOR
E RESET/ STANDBY INDICATOR
F TEMPERATURE CONTROL
G BURNER PRESSURE TEST POINT
H GAS PRESSURE ADJUSTMENT SCREW
J DATA LABEL

D

Diagram 6.1

10052

J

21

0020003579A

6 Commissioning

the ‘Burner On’ indicator going out and the lighting sequence
starting up, as follows:

1. Fan continues to run and then switches off / slows down.

2. After approximately 5 seconds fan restarts / speeds up.

3. After a short period sparking begins and the boiler attempts
to relight.

After shutting off the gas, the boiler will attempt to relight twice
before shutting 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 6.1.

To restart the lighting sequence, turn the temperature control
knob to "O" then fully clockwise to "Max". After approximately 10
to 15 seconds the boiler will begin its ignition sequence.

During Normal Operation when the boiler switches ‘Off’, the
burner will go out. The automatic lighting sequence will work
again when heat is required.

6.4 Testing - Gas

With the boiler on proceed as follows:

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 burner gas pressure at least 10 minutes after boiler
has lit, refer to Data Label, see diagram 1.2 and 1.3.

If necessary adjust the gas pressure to obtain the required
setting turning screw anti-clockwise, to decrease pressure, see
diagram 6.1.

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.

3

Gas rate: Hideaway 100C FF : 3.3m

Hideaway 115C FF : 3.8m3/h (136ft3/h)

is for guidance only, dependent on the heat setting.

Turn the boiler temperature control fully anti-clockwise to “0”.

Isolate from the electrical supply.

Remove the pressure gauge from the test point and refit screw,
making sure a gas tight seal is made.

When the boiler temperature control is turned to the “0” 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.

/h (115ft3/h)

6.5 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 Adjustment - Fully Pumped Open Vented
System

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.

6.8 Completion

Adjust the boiler temperature control and any system controls
to their required settings. In addition it is necessary to complete
the "Benchmark" logbook.

For IE, it is 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.

Fit the bottom plinth panel and secure with two dog point
screws, see diagram 6.2.

Finally fit the front panel by hooking under front of top panel
locating on the two studs and securing at the bottom on to the
bottom plinth panel with two screws, see diagram 6.3.

Testing Flue Gasses: If any doubt exists that the flue products
are not exhausting correctly. Investigate by the use of a gas
analyser (FGA).

BOTTOM
PLINTH

SECURING
SCREWS

LOCATE
UNDER LIP

LOCATING
STUDS

FRONT
PANEL

PANEL

Diagram 6.2

11838

12089

6.6 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.

0020003579A

FRONT PANEL
SECURING SCREWS

22

Diagram 6.3

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
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.

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.

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

Products of Combustion Check

NOTE: To obtain a products of combustion reading, remove the
front panel, see diagram 6.3 and remove the control box as
described in the relevant paragraphs of section 4.9. Next,
remove the cap from the sampling point, located on the top of
the left hand side of the inner casing, see diagram 8.1.

Connect the analyser tube on to the nipple.

WARNING: The multifunctional control and fan operate on
mains voltage, terminals will become live.

Switch on the electrical supply and gas supply then operate the
boiler.

On completion of the test switch off the electrical supply and 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.

Disconnect the ignition, sensing and earth leads from the
burner and remove by drawing the leads though the grommet,
see diagram 8.5 and 8.9.

Remove the three self-tapping screws from the lower part of the
control box support bracket, see diagram 8.6.

Undo the wing nut that secures the top of the heat shield and
carefully hinge down control box and heat shield, see diagram

8.6.

Release the three toggle latches that secure the boiler access
door and remove, see diagram 4.10.

SAMPLE POINT

12091

Diagram 8.1

8.1 Access

Remove the boiler front casing panel, refer to paragraph 6.8.

Remove the bottom plinth panel by unscrewing the two dog
point screws securing the panel to the boiler plinth, see diagram

8.4.

Disconnect gas valve from gas cock and unplug electrical plug
from gas valve, firstly removing electrical plug securing screw,
see diagram 8.2.

Unclip electrical wires from control box support bracket, see
diagram 8.3.

Undo the five self-tapping screws that secure the combustion
chamber front and carefully withdraw it together with the burner
and gas valve assembly, taking care not to strain the ignition,
sensing and earth leads, see diagram 8.5.

NOTE: When replacing burner in combustion chamber make
sure it fits correctly on the guides.

23

SECURING
SCREW

GAS SERVICE
COCK UNION

12165

ELECTRICAL
PLUG

Diagram 8.2

0020003579A

8 Servicing

NOTE: When replacing the fan access door make sure the lip
at the top of door fits into and behind the slotted bracket located
at the top of the boiler.

Refer to diagram 8.7.

Remove the electrical connections from the fan by pulling the
insulation boots only.

Disconnect the two air pressure tubes from the air pressure
switch and the red air pressure tube from the fan taking note of
their positions.

Remove the flue hood and fan assembly by sliding back to
disengage the retaining lugs then lift up.

When replacing the flue hood ensure that it rests on the guides
and that the rear of flue hood is located under the pegs at the
rear and pushed down and back fully.

IMPORTANT: When re-fitting fan check that it fits fully into the
flue duct extension piece.

12159

SECURING
SCREWS (4)

IGNITION, SENSING &
EARTH LEADS

GROMMET

COMBUSTION
CHAMBER COVER

WING NUT

12104

Diagram 8.5

0886

CONTROL BOX
SUPPORT
BRACKET

ELECTRICAL
WIRE
RETAINING
CLIPS

Diagram 8.3

11838

AIR
PRESSURE
TUBES (RED)

CONTROL BOX
SUPPORT
BRACKET

SELF
TAPPING
SCREWS
(3)

FAN
ELECTRICAL
CONNECTIONS

Diagram 8.6

AIR
PRESSURE
SWITCH

11829

BOTTOM PLINTH

PANEL

0020003579A

SECURING
SCREWS

Diagram 8.4

24

FLUE
HOOD

AIR PRESSURE
TUBE (CLEAR)

Diagram 8.7

8 Servicing

8.2 Boiler Flueways

Remove flueway baffles noting that there are 3 centre and 2
side flueway baffles, see diagram 8.8.

Place a sheet of paper in the combustion chamber to catch any
flue debris.

Thoroughly clean boiler flueways and fins with a suitable stiff
brush.

Replace in reverse order, after completing the relevant
instructions in sections 8.3 and 8.4.

8.3 Burners and Injectors

Remove the screws and nuts securing the burner support
bracket to the combustion chamber cover, see diagram 8.9.

Remove the graphite coated nuts on the supply feed pipe at the
rear of the burner to release the burner, see diagram 8.10.

Clean the burner. Use a vacuum cleaner or suitable stiff brush
(not wire) to clean the burner thoroughly, making sure that all
the burner ports are clear and unobstructed.

Check the burner injector for blockage or damage and replace
if necessary, see diagram 8.11.

With the burner removed the injector can be inspected and
cleaned as necessary.

For cleaning do not use a wire or sharp instrument on the hole.

If removed, use a little suitable sealant on the external thread
when refitting to make sure a gas tight seal is made.

8.4 Service Checks

Inspect the ignition and sensing electrodes and clean and
replace as necessary, see diagram 8.12.

Check the condition of the side and rear insulation panels in the
combustion chamber.

Check the condition of the seals on the boiler access door and
the combustion chamber cover.

Examine the flue hood and terminal to make sure they are clean
and clear of obstructions.

Refit all parts.

Testing Flue Gasses: If any doubt exists that the flue products
are not exhausting correctly. Investigate by the use of a gas
analyser (FGA).

Light the boiler and carry out functional tests as described in
section 6.

BURNER SUPPORT
SCREWS &
NUTS (2)

BRACKETS

12107

FLUEWAY
BAFFLE

SIDE
FLUEWAY
BAFFLE

HEAT
EXCHANGER

HEAT
EXCHANGER

12160

12027

IGNITION
ELECTRODE
(Black cable)

SENSING
ELECTRODE
(White cable)

GRAPHITE
COATED
NUT(2)

Diagram 8.9

12028

MAIN
BURNER

Diagram 8.8

25

SUPPLY
FEED
PIPE

Diagram 8.10

0020003579A

8 Servicing

ELECTRODE

12026

SECURING
SCREW

Diagram 8.12

GRAPHITE
COATED
NUT(2)

BURNER
INJECTOR

Diagram 8.11

0939

SPARK GAP

+

= 3.6 1.1

-

9 Fault Finding

IMPORTANT. On completion of the Fault Finding task which has required the breaking and remaking of the electrical connections,

the continuity, polarity, short circuit and resistance to earth checks must be repeated using a suitable multimeter.

WARNING: The multifunctional control and fan operate on mains voltage, the terminal will be live.

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/Standby indicator is lit - check water system for overheating, reset by turning temperature
control knob off and on. If the indicator 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.

12518

Control Knob at '0'

Ye s

Power ON at isolation switch

Ye s

Apply heating demand
(turn potentiometer clockwise)

Ye s

No No

Does the fan start

Ye s

Does the unit begin to spark

Ye s

Does the burner light

Ye s

Correct Operation

Is there an INDICATOR sequence

Ye s

Refer to table

No

No

Are the HT & Earth
connections made

Ye s

Refer to table

Ye s

Is there an INDICATOR sequence

Ye s

Refer to table

No

No

No

No

Replace PCB

Switch OFF
Remake connections
Restart diagnosis

Replace PCB

Turn Gas ONIs the Gas turned ON

Replace PCB

ELECTRICAL FAULT FINDING

0020003579A

Diagram 9.1

26

9 Fault Finding

BOILER TEMPERATURE
CONTROL

Diagram 9.2

9.1 Electrical

Gain access to the control box, refer to the relevant paragraph
in section 8.1, then remove the control box cover, refer to
section 5.1.

Refer to: Boiler Fault Finding, see diagram 9.1, Fault Finding
Wiring Diagram, see diagram 9.3, Pictorial Wiring Diagram, see
diagram 9.4.

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 and
the reset/standby indicator on the control panel is lit, turn the
burner temperature control to “0”, wait 30 seconds, then fully
clockwise to “Max.” see diagram 9.2.

10132

MAINS SUPPLY
230v ~ 50Hz

SL

bk

FUSE
TYPE F3.15A

AIR PRESSURE
SWITCH CONNECTIONS

MAIN TERMINAL
STRIP CONNECTIONS

PRINTED CIRCUIT
BOARD CONNECTIONS

KEY

bk BLACK
br BROWN
b BLUE
p PURPLE

b

br

br

p

r

gy

FAN

(N/O)

(C)

r RED
gy GREY
w WHITE

b

AIR
PRESSURE
SWITCH

11827

N

9.3 INDICATOR Fault Coding

Refer to fault coding table below.

w

SENSING
ELECTRODE

bk

br

EV2

bk

IGNITION
ELECTRODE

EV1

b

b

N

Diagram 9.3

27

0020003579A

9 Fault Finding

KEY TO

TERMINAL BLOCK

Ls = LIVE (Switched)
N = NEUTRAL
= EARTH MAIN

FAN

KEY

br BROWN
b BLUE
g/y GREEN/YELLOW
g GREY

b

p

IGNITION
ELECTRODE

JUMPER
POSITION

bk

bk BLACK
p PURPLE
r RED
w WHITE

THERMISTOR

bk

bk

P. C . B .
(CONTROL BOARD)

12419

AIR
PRESSURE
SWITCH

g

r

GAS
CONTROL
VALVE

g/y

b

br

bk

g/y

bk

b

T 3.15A
FUSE

RESET
INDICATOR

BURNER LIT
INDICATOR

bk

br

g

r

p

b

b

br

g/y

Ls N

b

BLOCK
CONNECTOR

g/y

MAINS SUPPLY
230V~50Hz

BOILER PILOT FAULT FINDING

0020003579A

Diagram 9.4

28

10 Replacement of Parts

Important notes

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

Replacement of parts must only be carried out by a competent
person.

Before removing or replacing any parts, turn off the gas supply
at the gas service cock, see diagram 8.2 and isolate the
electrical supply to the appliance.

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 carry out functional check of controls.

10.1 Electrical Thermistor

Remove front panel to gain access, see section 6.8.

Remove control box cover by undoing the four securing screws
(two on control box, two on the heat shield) and lift off, see
diagram 10.1.

Remove thermistor lead from retaining clip, located on the
control box support bracket, see diagram 8.3.

Release strain relief grommet securing thermistor lead at the
side of control box.

Disconnect the thermistor electrical plug from the control board
(P.C.B) slightly bending back the retaining latch to allow
withdrawal, see diagram 10.2.

Withdraw the electrical thermistor from its phial, see diagram

10.3.

Draw the thermistor lead followed by the thermistor out though
the control box case.

Re-assembly note. When fitting the thermistor make sure it is
fully inserted into the phial and secured using the grommet
moulded to the cable, see diagram 10.3.

SECURING
SCREWS

TERMINAL
BLOCK

BOILER
TEMPERATURE
CONTROL

CONTROL
BOX
COVER

12417

CONTROL
BOX

Diagram 10.1

PCB

12418

10.2 Control Board (P.C.B)

Remove front panel to gain access, see section 6.8.

Remove control box lid by undoing the four securing screws
(two on control box, two on the heat shield) and lift off, see
diagram 10.1.

Carefully pull the boiler temperature control knob away from the
P.C.B.

Disconnect the electrical plugs from the control board (PCB)
slightly bending back the retaining latches to allow withdrawal,
see diagram 10.2.

Disconnect the ignition, sensing and earth leads.

Carefully pull the board away from its supports bending back
slightly the retaining latches.

When refitting refer to wiring diagram 9.4.

Take care when replacing the burner temperature control knob
by supporting the potentiometer on the P.C.B.

NOTE: Ensure jumper is in position 'B', refer to wiring diagram

9.4.

10.3 Ignition and Sensing Electrodes

Remove front panel to gain access, see section 6.8.

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

To remove the electrode, unscrew from the retaining bracket,
see diagram 8.12.

Take the electrode out from below and disconnect the lead.

When removing and replacing the electrode take care not to
damage it.

When refitting, check spark gap, see diagram 8.12, 9.3 and 9.4.

EARTH LEAD

ELECTRICAL PLUGS

Diagram 10.2

PHIAL
POCKET

THERMISTOR

Diagram 10.3

10.4 Multifunctional Control

Remove front panel to gain access, see section 6.8.

Remove the securing screw and disconnect the electrical plug,
see diagram 10.4.

Disconnect the gas cock, on the left hand side.

Support the multifunctional control, remove the four screws (2
long, 2 short) from the flanged connection at the right 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 test for gas soundness and purge in accordance
with the current issue of BS6891or in IE, the current edition of
I.S.813 "Domestic Gas Installations".

12099

29

0020003579A

10 Replacement of Parts

10.5 Solenoid

Remove front panel to gain access, see section 6.8.

Remove the electrical plug from the multifunctional control and
remove the securing screw and then the solenoid assembly,
see diagram 10.4.

10.6 Burner

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

10.7 Injector

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

The injector can then be unscrewed from the manifold.

When replacing use a little jointing compound on the external
thread only, to ensure a gas tight seal.

10.8 Air Pressure Switch

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

Remove the air pressure tubes and electrical connections from
the switch, release the securing screws and remove the switch,
see diagram 10.5.

When fitting the replacement make sure that the air pressure
tubes are fitted with the clear tube from the air pressure switch
to the front fan connection, as shown in diagram 10.5 and the
electrical connections are made as shown in wiring diagram

9.4.

10.9 Fan

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

Remove the electrical connections and air pressure tubes from
the fan.

NOTE: Remove the electrical connections by pulling insulation
boots only.

Withdraw fan and flue hood assembly from boiler by taking hold
of fan, lifting slightly up and remove, see diagram 8.7.

Undo the screw securing the fan to the flue hood and disengage
fan from flue hood.

When re-assembling, make sure that the air pressure tubes are
fitted as before and that the fan duct engages fully into the flue
duct extension piece.

The polarity of the electrical connections is not important.

10.10 Insulation

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

Sides

Undo the burner support bracket nuts and remove support
bracket and insulation, see diagram 10.6.

Refit support bracket with new side insulation.

Rear

Bend forward rear insulation securing nibs, one on each side, to
release insulation.

Fit new insulation and bend back securing nibs.

AIR
PRESSURE
SWITCH

AIR PRESSURE
SWITCH
ELECTRICAL
CONNECTIONS

FRONT AIR
PRESSURE
SWITCH
TUBE (CLEAR)

REAR AIR
PRESSURE SWITCH
TUBE (RED)

Diagram 10.5

11829

SECURING
SCREW

GAS
SERVICE
COCK
UNION

0020003579A

SOLENOID
ASSEMBLY

ELECTRICAL
PLUG

SOLENOID
SECURING
SCREW

SHORT
SCREWS
(2)

Diagram 10.4

LONG
SCREWS
(2)

12167

30

BURNER SUPPORT
BRACKET

NUTS

SIDE INSULATION

12108

REAR
INSULATION
PANEL

Diagram 10.6

11 Spare Parts

11.1 Part Identification

The key number in diagram 11.1 and the first column of the list
will help identify the spare part.

1

2

5

6

7

11.2 Ordering

When ordering any spare part please quote the part number
and the description from the list together with the model name
and serial number information from the data label.

The data label is positioned on the heat shield, see diagram 6.1.

3

4

12519

9

8

Key No. Part No. Description GC Part No.

1 2000461898 Multifunctional control ******

2 227132 Fan ******

3 2000227137 Air pressure switch ******

4 2000461793 Electrical thermistor ******

5 202635 Ignition electrode (R/H Burner) ******

6 202635 Sensing electrode (L/H Burner) ******

7 2000461714 Boiler temperature control knob ******

8 2000461897 Injector 100C FF ******

8 205746 Injector 115C FF ******

9 202240 Fuse ******

10 2000461896 Control board ******

11 205657 Double Burner ******

10

11

Diagram 11.1

31

0020003579A

Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

0020003579A

32