Glow-worm Ultimate 100FF User Manual

Instructions for Use

Installation and Servicing

To be left with the user

100FF 120FF

G.C. No. 41 047 59 G.C. No. 41 319 75

221966B.12.04

4272

Fanned Flue Boiler

BS 6332
BS 5258

This is a Cat I2H 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:

✔

All replacement parts

❏

✔

All labour charges

❏

All call-out charges

✔

❏

REGISTER YOUR GLOW-WORM APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0800 073 2142

Glow-worm,

Tel: [phone]

Fax: [phone]

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: [phone] Fax: [phone]

www.glow-worm.co.uk

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 Regulation 5 certified by: Notified body 0086.

Product/productioncertifiedby: 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.

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.

REFRACTORY CERAMIC FIBRE

This product uses insulation material containing Refractory Ceramic Fibre (RCF), which are man-made vitreous silicate fibres.
Excessive exposure to these materials may cause temporary irritation to eyes, skin and respiratory tract, consequently, it makes
sense to take care when handling these articles to ensure that the release of dust is kept to a minimum.

To ensure that the release of fibres from these RCF articles is kept to a minimum, during installation and servicing we recommend
that you use a HEPA filtered vacuum to remove any dust accumulated in and around the boiler before and after working on the boiler.
When replacing these articles we recommend that the replaced items are not broken up, but are sealed within heavy duty polythene
bags, clearly labelled as RCF waste. This is not classified as “hazardous waste” and may be disposed of at a tipping site licensed
for the disposal of industrial waste. Protective clothing is not required when handling these articles, but we recommend you follow
the normal hygiene rules of not smoking, eating or drinking in the work area and always wash your hands before eating or drinking.

INSULATION PADS, GLASSYARN.

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 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 Glow­worm.

221966B

2

Important Information

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

SERVICING

INSTRUCTIONS

Introduction 3
Lighting the Boiler 5

General Data 1 6
Flue Terminal 2 9
Water Systems 3 10
Flue and Appliance Preparation 4 13
Boiler Installation 5 17
Flue Fixing 6 19
Electrical Connectors 7 20
Commissioning 8 21
Instructions to the User 9 24

Servicing 10 24
Fault Finding 11 27
Replacement of Parts 12 31
Spare Parts 13 34

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.

IMPORTANT NOTICE

This boiler is for use only on natural gas (G20).

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.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.

3 221966B

Instructions for Use

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 your 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.

CONTROLS COVER

30FF to 60FF Ultimate User Controls illustrated, details
for the 70FF to 120FF are different but the controls are
the same.

DATA &

VIEWING WINDOW

4625

SERIAL
NUMBER
LABEL

RESET
BUTTON

4140

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.

Boiler Electrical Supply

WARNING: This boiler must be earthed.

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 I.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

2

(24/0.20mm).

CONTROL
THERMOSTAT
KNOB

SETTING POINT

GAS SERVICE
COCK (Shown
Off)

Diagram 1

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

.

221966B

4

Instructions for Use

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 pressure gauge should show at least 0.7bar, anything less
than this figure could indicate a leak and you MUST contact your
installation/servicing company.

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

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.

o

C (180oF), see diagram 1.

6mm

Additional clearances may be
required for installation

160mm

6mm

500mm

65mm

6mm

6mm

6mm

FRONT
VIEW

0208M

Diagram 2

To Turn the Boiler Off

For short periods, turn the control thermostat knob anti-clockwise
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 anti­clockwise 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.

5 221966B

B

AO

1 General

C

PUMPED

FLOW

PUMPED

RETURN

F

G

H

0301M

E

J

SIDE ELEVATION FRONT ELEVATION

MODEL

100FF,120FF

D

ABCDEFGHJ KLMO

67 300 58 127 114 450 168 132.5 835 772 63 132 43

WATER CONNECTIONS
28mm COPPER PIPE

GAS CONNECTIONS

1

RC

/2 (1/2 in. BSPT)

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 hot water can
only be provided by pumped circulation to the indirect cylinder.

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.

P

C

L

K

L

M

P

78.5

Diagram 1.1

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 Data

See Table 1

All dimensions are given in millimetres (except as noted).

*NOTE: Lift weight is with Flue Elbow, Controls Cover and Front
Cover removed.

The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
Ultimate 100FF = 79, Ultimate 120FF = 78.1.

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.

1.3 Range Rating

This boiler is range rated and may be adjusted to suit individual
system requirements.

Table 2 gives the ratings and settings.

221966B

6

1 General

DATA TABLE 1.

MODEL

100FF

120FF

TOTAL DRY
WEIGHT
(Including

71.0 kg
(157 lb)

71.0 kg
(157 lb)

Terminal)

*

LIFT WEIGHT

WATER
CONTENT

GAS
CONNECTION

ELECTRICITY
RATING

WATER
CONNECTION

ELECTRICITY
SUPPLY

DATA LABEL

63.3 kg
(140 lb)

3.8 litres

(0.84 gal)

Rc 1/2 in.

71W 97W

Internal fuse F1 & F2 (F1A)

2x28mm copper pipes from

top of case

230V~50Hz, fused 3A

Bottom right hand side of case

63.3 kg

(140 lb)

3.8 litres

(0.84 gal)

1.4 B.S.I. Certification

This boiler is certificated to the current issue of BS6332 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 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 Supply

WARNING: This boiler must be earthed.

All system components shall be of an approved type and shall
comply with and 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 I.S.813 "Domestic Gas
Installations".

Connection of the boiler and system controls to the mains
supply must be through a common isolator and must be fused
3A, maximum. This method of connection must be by a fused
double pole isolating switch with a minimum contact separation

TABLE 2. 100FF

9072

RANGE RATING

NOMINAL
HEAT
INPUT(NETT)

NOMINAL
HEAT
OUTPUT

BURNER.
SETTING
PRESSURE

in. wg.

APPROX.
GAS
RATE

Btu/h

Btu/h

m bar

m

ft

kW

kW

3

/h

3

/h

Min.

26.44

90,210

23.45

80,000

9.2

3.7

2.8

100

29.24

99,760

26.38

90,000

11.6

4.7

3.1

111

BURNER INJECTOR MARKING:

BURNER INJECTOR SIZE:

205727

4.7mm

TABLE 2. 120FF

RANGE RATING

NOMINAL
HEAT
INPUT(NETT)

NOMINAL
HEAT
OUTPUT

BURNER.
SETTING
PRESSURE

in. wg.

APPROX.
GAS
RATE

Btu/h

Btu/h

m bar

m

ft

Min. Max.

kW

33.43

114,066

kW

29.3

100,000

Medium.

124,608

110,000

9.9

4.0

3

/h

3.5

3

125

/h

36.52

32.24

12.0

4.8

3.9

137

BURNER INJECTOR MARKING: 205726

BURNER INJECTOR SIZE: 5.2mm

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 easilyidentifiable 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 insulated type to the current
issue of BS6500 Table 16.

1.7 Contents of Packaging

The boiler is delivered in one pack, refer to Section 4.1 for
contents.

Refer to Section 4.2 to check that the flue terminal assembly
supplied is suitable.

1.8 Water System

This boiler may be fitted to an open vented or sealed water
system.

9715

Max.Med.

32.38

110,485

29.31

100,000

14.4

5.8

3.5

123

39.6

135,150

35.17

120,000

14.2

5.7

4.2

148

7 221966B

1 General

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

0208M

1.9 Drain

System

A draining tap must be provided at the lowest points of the
system which will allow the 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 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.

1.11 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 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 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 1.2.

The boiler must be positioned so that at least the minimum
operational and servicing clearances are provided.

Additional clearances may be required for installation.

If fixtures are positioned next to the boiler they should be made
removable for access to pipework.

Sufficient clearance must be left in front of the boiler for
servicing.

1.13 Room Ventilation

The boiler is room sealed and does not require the room or
space containing it to have permanent airvents.

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,
permanent high and low level ventilation must be provided. The
minimum ventilation areas are given in Table 3.

221966B

6mm

Additional clearances may be
required for installation

160mm

6mm

500mm

65mm

6mm

PLAN
VIEW

6mm

6mm

FRONT
VIEW

MINIMUM CLEARANCES FROM WALLS CEILING,
FLOOR, CUPBOARD, WORKTOPS, AND
INFLAMMABLE MATERIALS

TABLE 3. COMPARTMENT AIR VENTS

VENTILATION
REQUIREMENTS

MODEL

VENTILATION
FROM
ROOM
OR SPACE

VENTILATION
FROM
OUTSIDE

100FF

120FF

100FF

120FF

HIGH LEVEL
VENT AREA

2

cm

330 51 330 51

396 61.5 396 61.5

165 25.5 165 25.5

198 30.5 198 30.5

in2cm2in

Diagram 1.2

LOW LEVEL
VENT AREA

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. If in doubt seek advice from the local
gas undertaking or Glow-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.

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.

8

0209M

2 Flue Terminal

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 diagram 2.1. For Ireland the minimum distances for
flue terminal positioning must be those detailed in I.S.813
"Domestic Gas Installations".

The terminal must be exposed to the external air, 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

A

B,C

A

F

G

Under Car Port etc.

MINIMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS POSITION

A DIRECTLY BELOW, ABOVE OR HORIZONTALLY

TO AN OPENING, AIR BRICK, OPENING WINDOWS,

AIR VENT OR ANY OTHER

VENTILATION OPENING. 300

B BELOW GUTTER, DRAIN/SOIL PIPE 75

C BELOW EAVES 200

D BELOW A BALCONY OR CAR PORT 200

E FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25

F FROM EXTERNAL CORNERS 25

G ABOVE ADJACENT GROUND OR BALCONY LEVEL 25

H FROM A SURFACE FACING THE TERMINAL 600

I FACING TERMINALS 1200

J FROM OPENING (DOOR/WINDOW) IN

CAR PORT INTO DWELLING 1200

K VERTICAL FROM A TERMINAL 1500

L HORIZONTALLY FROM A TERMINAL 300

M FROM INTERNAL CORNERS 25

G

A

E

G

H,I

B,C

K

M

F

F

G

J

C

K

L

L

K

G

D

F

K

SPACING in mm

MINIMUM

0103M

4307

Diagram 2.1

9 221966B

Flow rate (litres/minute)

Water pressure loss

(mm head of water)

PRESSURE LOSS
OF BOILER 100FF/120FF

Design Flow Rate

0088(z)M

750

500

250

0

0 5 10 15 20 25 30 35 40 45

700mm (120FF)

450mm (100FF)

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 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.

3.1 Frost Protection

If the position of the boiler is such that it may be vulnerable to
freezing it should be protected as specified in the current issue
of BS5422. It is 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 11oC (20o), between the flow and
return, with the control thermostat set at “MAX”, which is about
82oC (180oF).

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 MUST be fitted to a fully pumped and sealed water
system.

Where the water system allows the boiler and pump to operate
on bypass only, the bypass connection must be at least 2.5metres
away from the boiler.

The flow through the boiler must not be allowed to fall such that
there is a temperature difference greater than 20
flow and return.

o

C between the

Diagram 3.1

3.6 Indirect Cylinder

For all systems supplying domestic hot water the cylinder must
be indirect. It is recommended that the indirect cylinder be fitted
with some form of temperature control.

3.7 Fully Pumped Heating and Domestic Hot
Water

The connections for this type of system MUST be as shown in
diagram 3.2 and 3.3.

3.8 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, contact a manufacturer or Glow­worm, 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 the radiators, then thoroughly
cleaning out before installing the boiler whether or not adding an
inhibitor.

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 pump, cold feed
and open vent are as shown in diagram 3.2.

The unrestricted open vent from the boiler must rise continuously
to over the feed and expansion cistern.

3.5 Domestic Hot Water System

General - All domestic hot water circuits, connections, fittings

must be in accordance with the relevant standards and water
supply regulations.

For GB: Guidance G17 to G24 and recommendation R17 to
R24 of the Water Regulations Guide.

For IE: The current edition of I.S.813 "Domestic Gas Installations".

The domestic hot water service must be in accordance with the
current issue of BS5546, refer also to the current issue of
BS6700.

221966B

3.9 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 3.4 for a suggested layout.

3.10 Safety Valve

A safety valve must be fitted to a sealed water system.

It shall be preset, nonadjustable with a lift pressure of 3bar,
incorporating seating of resilient material, a test device and a
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.

10

3 Water Systems

OPEN VENTED FULLY PUMPED WATER SYSTEM
RECOMMENDED RELATIONSHIP BETWEEN
PUMP COLD FEED AND VENT

6349

22mm VENT
450mm
MIN.
HEIGHT

(MIN.)

FEED AND
EXPANSION
CISTERN

15mm (MINIMUM)
COLD FEED

1150mm
MIN.

RETURN

CYLINDER

FLOW

PUMP

There must
always be a
cold water
path to the
return
connection
of the boiler.

BOILER

150mm
MAX.

28mm (MINIMUM)

BY-PASS WITH

FLOW

HEATING

RET.

LOCKSHIELD VALVE

Diagram 3.2

3.11 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 3.4, unless laid down differently by the
manufacturer.

The expansion vessel volume depends upon the total water
system volume and the initial system design pressure. For any
system an accurate calculation 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.

3.12 Pressure Gauge

A pressure gauge with a set pointer and covering at least the
range of 0 to 4bar (0 to 60lb/in
the system in a position where it can be seen when filling the
system.

2

) shall be permanently fitted to

FLOW

28mm
PIPE

22mm VENT & 15mm COLD FEED
TO BE FITTED IN ACCORDANCE
WITH BS 5449

INDIRECT
CYLINDER

1metre Min.

27 metres

Max.

FULLY PUMPED CIRCULATION
BYPASS (DIAGRAMMATIC)

1metre Min.

27 metres

Max.

BYPASS 28mm
MIN WITH
LOCKSHIELD
VALVE

PUMP

22mm FOR COMBINED FEED & VENT
TO BE FITTED IN ACCORDANCE
WITH BS 5449

INDIRECT
CYLINDER

BYPASS 28mm
MIN WITH
LOCKSHIELD
VALVE

PUMP

RETURN

4273

6459

HEATING
SYSTEM

ALTERNATIVE
SYSTEM
CONTROL
VALVES

6466

HEATING
SYSTEM

ALTERNATIVE
SYSTEM
CONTROL
VALVES

FULLY PUMPED CIRCULATION
BYPASS (DIAGRAMMATIC)

Diagram 3.3

11 221966B

(Make-up

(Make-up

alternatives)

alternatives)

3 LITRES (0.66 gals)
MAKE-UP BOTTLE
(if required)

NON-RETURN
VALVE

HEATING

CIRCUIT

3 Water Systems

AUTO
AIR
VENT

FLOW

22mm (min)
BY-PASS WITH
LOCKSHIELD
VALVE

RETURN

DRAIN
COCK

SAFETY
VALVE

BOILER

6252

AIR
RELEASE
POINT

FILLING POINT

CIRCULATING
PUMP

PRESSURE
GAUGE

EXPANSION
VESSEL

METHOD 1

TEMPORARY
HOSE

SUPPLY
PIPE

METHOD 2

TEMPORARY
HOSE

SUPPLY
PIPE

METHOD 3

CISTERN

SUPPLY
STOP VALVE

SUPPLY
PIPE

HOSE
UNIONS

SUPPLY STOP
VALVE

DOUBLE CHECK
VALVE ASSEMBLY

HOSE
UNIONS

SUPPLY STOP
VALVE

OVERFLOW

SERVICING
VALVE

HOSE
UNIONS

COMBINED
CHECK VALVE
AND VACUUM
BREAKER

SERVICING
VALVE

SERVICING
VALVE

PRESSURE
REDUCING
VALVE

DOUBLE CHECK
VALVE ASSEMBLY

0051M

HEATING
SYSTEM

HEATING
SYSTEM

HEATING
SYSTEM

Diagram 3.5

Diagram 3.4

3.13 Domestic Hot Water Cylinder

SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE.

The domestic hot water cylinder must be if the indirect coil type.
It must be suitable for working at a gauge pressure of 0.35bar
above the safety valve setting.

3.14 Domestic Hot Water System - Unvented

Where a storage system will not have a vent to atmosphere the
installation must comply with Building Regulations and the
Local Water Company Byelaws, see also the current issue of
BS6700.

If fitting into an existing system, the local authority must also be
advised.

3.15 Filling a Sealed Water System

Provision for filling the system at low level must be made. Three
methods are shown in diagram 3.5. There must be no permanent
connection to the mains water supply, even through a non­return valve.

3.16 Water Makeup

Provision must be made for replacing water lost from the
system. A make up vessel mounted above the highest point of
the system and connected through a non-return valve to the
system on the return side of either the hot water cylinder or
heating system, see diagram 3.4.

Alternatively provision for make up can be made by a filling loop.

221966B

12

4 Flue and Appliance Preparation

4.1 Unpacking

Open the carton, check the items supplied against the boiler
pack contents list on the flap, see diagram 4.1.

4.2 Flue Position and Length

Determine flue applications, length and terminal position before
starting.

Refer to diagram 4.2 or 4.3.

NOTE: If a longer flue duct is required DO NOT extend the
ducting.

A 1, 2 or 3metre flue system and terminal MUST be used, for the
100FF and 1 or 2 metre only for the 120FF.

NOTE: If required, an optional Wall Liner Kit, part No.452481,
is available, complete with fixing instructions.

4.3 Flue Preparation

All flue 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.

If there is insufficient clearance the flue can be installed from
outside.

CARTON

4792

For a wall thickness up to 300mm, provided that there is
sufficient space and the optional wall liner kit is 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.

4275

'R'

Standard Flue terminal illustrated.

REAR FLUE LENGTHS

Distance R = Wall thickness

WALL
TEMPLATE

BOILER

STD. 75mm to 438mm

1M 75mm to 928mm

2M 75mm to 1928mm

*3M 75mm to 2928mm *100FF ONLY

Diagram 4.2

6854

'S'

Standard Flue terminal illustrated.

SIDE FLUE LENGTHS

LOOSE
ITEMS PACK

MOUNTING
BRACKET

INSTRUCTIONS

Diagram 4.1

Distance S = External wall face to boiler case

STD. 81mm to 346mm

1M 81mm to 830mm

2M 81mm to 1830mm

*3M 81mm to 2830mm *100FF ONLY

Diagram 4.3

13 221966B

4 Flue and Appliance Preparation

4.4. Rear and Side Flue Application

Take the template from the boiler pack and 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. Mark the position of the centre of the flue and boiler, then
remove template as diagram 4.4.

4277

120 mm
MINIMUM
HOLE

4.5 Flue Hole Cutting

Having marked out the flue centre cut a hole for the flue using,
preferably, a 120mm 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.

NOTE: the mounting bracket has additional holes to allow for
further fixings should site conditions require it.

Drill holes and plug, to suit No.12x2in woodscrews, 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
woodscrews and plugs, see diagram 4.5.

If the boiler is not to be fitted for some time, cover the hole in the
wall.

127mm

SIDE FLUE

FLUE/BOILER
CENTRE LINE

Diagram 4.4

4278

TOP BOILER
MOUNTING
HOLES

TEMPLATE

FLUE/BOILER
CENTRELINE

172

172.5

7dia.

194

172.5

3/16in. dia.
PLUG

749

MOUNTING
BRACKET FIXING
POINTS

NO.
12x2in.

65.5

FLUE/BOILER
CENTRELINE

5mm

BOILER
MOUNTING
BRACKET

Diagram 4.5

221966B

14

4 Flue and Appliance Preparation

4.7 Flue Length

For a rear flue, measure the distance from the outside wall face
to the boiler mounting wall. Check that the flue length will be
suitable, see diagram 4.2.

For a side flue, measure the distance from the outside wall face
to the boiler centre line. Check that the flue length will be
suitable, see diagram 4.3.

All 2 and 3 metre flue systems are installed in a similar manner
to the standard flue.

4.8 Rear Flue

Mark the air duct/terminal assembly and the flue duct at the
length shown in diagram 4.6 and 4.8 then cut to length, cutting
square and removing any burrs.

NOTE, do not cut the flue duct at the pre-drilled end.

4.9 Side Flue

Mark the air duct/terminal assembly and the flue duct at the
lengths shown in diagram 4.7 and 4.9 then cut to length, cutting
square and removing any burrs.

NOTE, do not cut the flue duct at the pre-drilled end.

4.10 Flue Assembly

Locate the flue duct (drilled end) onto the flue elbow and secure
with the screws supplied in the loose items pack, see diagram

4.10.

Locate the flue duct/elbow into the air duct/terminal spigot and
the air duct/terminal into the flue elbow making sure the correct
alignment of top. Drill the air duct and secure/seal (external
fixing, do not seal) as shown in diagram 4.10.

6856

T MINUS 55mm

BOILER

CENTRE

LINE

T

4.11 Wall Liner

If a wall liner is used, fit foam seal as diagram 4.11.

6855

FLUE

DUCT

Q PLUS 72mm

Q

Diagram 4.7

6857

LONG FLUE

TERMINAL

STANDARD FLUE
TERMINAL

Q PLUS 72mm

Q

Diagram 4.6

Diagram 4.8

15 221966B

4 Flue and Appliance Preparation

6858

LONG FLUE

TERMINAL

BOILER

CENTRE

LINE

STANDARD FLUE
TERMINAL

T MINUS 55mm

T

FOAM

SEAL

20mm

WALL THICKNESS­UP TO 300mm

FOAM

SEAL

Q MINUS 55mm

6859

Q

Q

FLUE ELBOW

FLUE DUCT

NOTE:

THE FLUE TERMINAL
RESTRICTOR MUST BE
POSITIONED AS SHOWN

Diagram 4.9

WALL THICKNESS­OVER 300mm

Diagram 4.11

4284

SECURING
SCREW (2)

SEALING TAPE

AIR DUCT/
TERMINAL

221966B

FLUE ELBOW
DUCT

3mm
DRILL

STANDARD FLUE TERMINAL

Diagram 4.10

16

5 Boiler Installation

5.1 Boiler Preparation

With the boiler still in the bottom tray, slide the controls cover
upwards and remove it as shown in diagram 5.1.

Remove the front cover by undoing (and keeping) the wing nut,
nut and shakeproof washer, then lift the front cover off, see
diagram 5.1.

Place the front cover on one side until required, having removed
the polystyrene packing piece.

Fit suitable compression fittings to the boiler connections.

5.2 Mounting the Boiler

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) on to it,
see diagram 5.2.

4285

CONTROLS
COVER

Remove the blue and red electrical connections from the fan,
see diagram 5.3.

Break the air pressure switch tube connections from the fan,
see diagram 5.3.

Remove the fan assembly by removing the screws and sliding
out, see diagram 5.3. Take care not to damage the gasket.

Slacken, but do not remove, the flue hood securing screws, see
diagram 5.4.

WING
NUT

FRONT
COVER

NUT

SHAKEPROOF
WASHER

SWING
BRACKET

SECURING
SCREWS (2)

4286

5mm

Pipe
omitted
for clarity

Diagram 5.1

MOUNTING
BRACKET

Diagram 5.2

17 221966B

5 Boiler Installation

5.3 Water Circulation System

Complete the water connections to the boiler.

Fill, vent and flush system.

Check for any leaks and put right.

5.4 Safety Valve Discharge

Fit a suitable discharge pipe to the safety valve and route it
outside the building so that any discharge can be seen but will
not cause injury to person, damage to property or any electrical
installation.

5.5 Gas Connection

Make the gas connection to the Rc 1/2in gas service cock, see
diagram 5.5.

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".

4287

ELECTRICAL
CONNECTIONS

FAN SECURING
SCREWS

RED

CLEAR

CLEAR

AIR PRESSURE
SENSING PIPES

FLUE HOOD
SECURING
SCREW (4)

FAN
ASSEMBLY

FLUE
HOOD

FAN
SECURING
BRACKET

FLUE HOOD
SECURING SCREWS (4)

UNION NUT

4288

Diagram 5.4

4289

221966B

Diagram 5.3

GAS SERVICE COCK
(SHOWN OFF)

Diagram 5.5

18

6 Flue Fixing

NOTE: If external flue fixing is required start at 6.2.

6.1 Flue Fixing - Internal

NOTE: Use of the optional wall liner kit is required.

Place the flue assembly into the hole. Check that the flue
terminal is correctly positioned and is the distance required from
the outside wall face, see diagram 6.1.

Position flue elbow gasket and secure the flue assembly to the
boiler using the dogpoint screws, see diagram 6.2.

Make sure of the correct fitting of the flue to the boiler.

Now continue at Section 6.3.

6.2 Flue Fixing - External

Remove the flue elbow from the air duct/terminal and flue duct,
by removing and keeping, the securing screw(s).

From outside place the air duct/terminal and flue duct assembly
into the hole and make sure that the flue terminal is correctly
positioned and is the distance required from outside wall face,
see diagram 6.1.

Position flue elbow gasket and secure the flue elbow to the
boiler using the dogpoint screws, see diagram 6.2.

Make sure of the correct fitting of the flue to the boiler.

Pull the flue duct forwards and engage onto the flue elbow.

Push the air duct back into the wall to the dimension shown in
diagram 6.3.

Important, the flue duct will become disengaged should the
dimension be any greater than shown.

Hold the flue duct onto the flue elbow, then, secure the flue duct
to the flue elbow, see diagram 6.3.

Pull the air duct back to engage with

the flue elbow and secure/seal.

6.3 All Flue Installations

Fit the fan to the flue elbow spigot and secure with the screws
previously 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

5.3.

Secure the flue hood, see diagram 5.4.

152 DIA

CORE

DRILLED

HOLE

FLUE
TERMINAL

OUTSIDE
WALL FACE

SECURING
SCREW (4)

FLUE ELBOW

58

GASKET

AIR
DUCT

WALL FACE

✽ 30mm

FLUE DUCT

✽

30mm

Diagram 6.1

Diagram 6.2

FLUE
ELBOW

0181M

4290

7005

3mm Drill

Sealing
Tape

FLUE
DUCT/
ELBOW

✽ Maximum dimension! Otherwise the flue duct will

become disengaged.

19 221966B

Diagram 6.3

7 Electrical Connectors

7.1 Control Box Removal

Remove the electrical control box securing screws, see diagram

7.1. Slide the box forwards and release, hook it onto the lip
bracket at the front, see diagram 7.1.

7.2 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.

Using heat resistant (to 85

0.2mm) to the current issue of BS6500 Table 16 and of suitable
length, thread through the cable clamps, secure into the plastic
clips and connect to appropriate terminals, see diagram 7.2 and

11.5.

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

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.

NOTE: Open Vented Water Systems ONLY.

Bridge terminals K1 and K2.

o

C) cable of at least 0.75mm2 (24/

9079

SECURING
SCREWS (2)

LIP BRACKET

7.3 Pump Connection

The pump must be connected directly to the control box, as
shown in diagram 7.2, threading the cable through the cable
clamp in the side of the control box.

7.4 External Controls

Any external controls must only be wired to interrupt the red link
between terminals SL and 9.

Make sure that the supply cable and all external cables are
secured and away from hot surfaces.

7.5 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 of the controls scheme used with the boiler.

4136

MAINS
CABLE

✽

RED
LINK

PUMP
CABLE

IGNITION LEAD

Diagram 7.1

NOTE: Bridge
terminal K1 & K2
on an Open
Vented System
only

PUMP
CABLE

221966B

CABLE

CLAMPS
MAINS
CABLE

✽ Remove red link between 9 & SL when fitting
a time control etc (If no switch is fitted, link will
make the circulation pump run constantly).

Diagram 7.2

20

8 Commissioning

Please ensure the "Benchmark" logbook is completed and left
with the user.

8.1 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, making sure 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.

8.2 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/in2). Clear any air locks and check for water
soundness.

Check the operation of the safety valve, by allowing the water
pressure to rise until the valve opens. The valve should open
within +/-0.3bar (+/-4.3lbf/in2) 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.

SETTING

POINT

CONTROL
THERMOSTAT

CLEANING PLATE

OVERHEAT
SAFETY
CUT-OFF

GAS SERVICE COCK
(SHOWN OFF)

SECURING
SCREW (8)

4291

Diagram 8.1

4292

8.3 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 8.1.

Check that the boiler is isolated from the electrical supply.

Make sure that the control thermostat is turned to “O” the “Off”
position.

Turn boiler gas service cock “On”.

Test the pilot supply tube and its connection for gas soundness
as follows:

Disconnect the ignition lead from the PCB, see diagram 7.2.

Remove the combustion chamber front, see diagram 8.2.

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 pilot 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.

The pilot flame length should be as shown in diagram 8.3.

Turn the control thermostat knob to “O” and isolate the boiler

SECURING
SCREW

COMBUSTION
CHAMBER
FRONT PANEL

from the electrical supply.

Fit the combustion chamber front.

Reconnect the ignition lead to the PCB.

For future reference, stick the self adhesive arrow indicator to
the data label, against the rating that the boiler is going to be set
to. The arrow is in the loose items pack.

Loosen the main burner pressure test point screw and connect
a suitable pressure gauge, see diagram 8.4.

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.

VIEWING
WINDOW

Diagram 8.2

21 221966B

8 Commissioning

8.4 Testing - Electrical

Turn the control thermostat knob fully clockwise to the maximum
setting, which is about 82

The lighting sequence is automatic as follows:

The fan operates

The Spark ignition operates

The pilot solenoid opens

The pilot burner lights

o

C (180oF), neon 2 will light.

Neon 3 will light

}

4146

10 to 20mm FLAME LENGTH

The ignition spark stops

The main solenoid opens

and after a short period of time the main burner will light, look
through viewing window, see diagram 8.2.

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:

Very cold weather may delay the operating sequence.

1. With the main burner alight, turn the gas service cock “Off”,
see diagram 8.1.

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

11.1.

4. To carry on turn the gas service cock “On”, see diagram 8.1.

When the boiler switches “Off”, both the pilot and the main
burner go out. The automatic lighting sequence will work again
when heat is required.

Neon 4 will light

}

NOTE:

PILOT SHIELD
REMOVED FOR
CLARITY

ULTIMATE 100FF

4293(1)

4139

SPARK GAP

2.5 to 4mm

10 to 20mm FLAME LENGTH

8.5 Testing - Gas

With the boiler on proceed as follows:

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".

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
setting turning the screw clockwise, to decrease pressure, see
diagram 8.4.

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.

Turn the control thermostat knob fully anticlockwise to “O”.
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 “Off” position, by hand,
wait at least 30 seconds before turning “On” again.

There may be an initial smell given off from the boiler, this is
quite normal and will disappear after a short period of time.

Refit the electrical controls box, see diagram 7.1.

NOTE: The neon indicators on the printed circuit board are an
aid to fault finding, for details refer to Section 11.

NOTE:

PILOT SHIELD
REMOVED FOR
CLARITY

ULTIMATE 120FF

SPARK GAP

2.5 to 4mm

4293(2)

Diagram 8.3

221966B

22

8 Commissioning

8.6 Testing - Open Vented

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 be turned off and the system
drained off as rapidly as possible, whilst still hot.

8.7 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
and return.

UNDER NO CIRCUMSTANCES SHOULD THIS VALVE BE
LEFT IN THE FULLY CLOSED POSITION.

o

C between the flow

8.8 Sealed Water System ONLY

Adjust system to initial design pressure. The set pointer on the
pressure gauge should be set to coincide with the indicating
pointer.

8.9 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 current issue of BS7478 for guidance.

TOP
SEAL

FRONT
COVER

SIDE
SEAL

4295

GAS
PRESSURE
ADJUSTMENT
SCREW

MULTI­FUNCTIONAL
CONTROL

MAIN BURNER

NOTE:

DO NOT ADJUST ANY
OTHER SETTING SCREWS

PRESSURE TEST SCREW

Diagram 8.4

4294

WING
NUT

SLIDERS

WASHER

NUT

Diagram 8.5

4140

RETAINING
CLIP

CONTROLS

COVER

Diagram 8.6

23 221966B

8 Commissioning

8.10 Operational Checks and Completion

Adjust the control 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.

Fit the front cover by hooking it under at the top and securing
with the screws previously removed, see diagram 8.5.

Fit the controls cover by hooking into the sliders and pushing it
back as far as it will go, see diagram 8.6.

9 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.

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

8.11 Protection against Freezing

If the boiler is to be out of use for a period of time during severe
weather conditions we recommended that the whole of the
system, including the boiler, be drained off to avoid the risk of
freezing up.

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 the 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, 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.

10 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 the 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.

10.1 Access

Refer to diagram 8.6 and slide controls cover forward and off.

Remove the outer case, see diagram 8.5.

NOTE: As an aid to servicing the air pressure switch tube
connections 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.

SECURING NUT AND

SHAKEPROOF

WASHER

ELECTRODE AND

LEAD ASSEMBLY

UNION
CONNECTOR

4094

PILOT PIPE

Diagram 10.1

221966B

24

10 Servicing

10.2 Cleaning Heat Exchanger and Burner

Disconnect the air pressure tubes, see diagram 5.3.

Remove the blue and red electrical connections from the fan,
see diagram 5.3.

Remove the fan taking care not to damage the gasket, see
diagram 5.3.

Remove the flue hood, see diagram 5.4.

Remove the combustion chamber cover, see diagram 8.2.

Remove the cleaning plate from the combustion chamber
cover, see diagram 8.2.

Disconnect the pilot pipe union connector and 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 10.1.

Remove the securing screw from the burner support bracket,
see diagram 10.2.

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 not to damage the combustion chamber insulation
or the pilot pipe.

Use a vacuum cleaner or suitable stiff brush to clean the burner
thoroughly, making sure that all the burner ports are clear and
unobstructed.

Place a sheet of paper in the base of the combustion chamber.

100 FF ONLY

Remove the baffles, see diagram 10.3.

If a vertical or flue bend systems, using corrugated bends, see
Flue Kit Installations, has been fitted then the TOP FLUE
BAFFLES will have been REMOVED.

NOTE: When replacing the bottom three baffles, the two half
and one whole baffle, make sure that they are positioned with
the mark “100” to front of appliance as shown in diagram 10.3.

4296

SECURING
SCREW

9642

BURNER
SUPPORT BRACKET

Diagram 10.2

BAFFLE (6)

HEAT
EXCHANGER

120 FF ONLY

Remove the baffles, see diagram 10.4.

NOTE: When replacing the bottom baffle, make sure that it is
positioned with the word “Bottom” to front of appliance as shown
in diagram 10.4.

Continued-

The heat exchanger can now be cleaned, paying particular
attention to the gap between the fins, with a suitably sized semi­stiff brush, using the cleaning plate, as shown in diagram 10.5,
to protect the rear insulation panel.

Remove the paper together with any debris.

10.3 Main Injector

With the main burner removed the main injector can be inspected
and cleaned as necessary, see diagram 10.6.

If removing for cleaning do not use a wire or sharp instrument
on the hole.

Use a little suitable sealant on the external thread when refitting
to make sure a gas tight seal is made.

NOTE: On refitting and after cleaning the heat exchanger make
sure the burner is fitted correctly, that is, located on the main
injector and horizontal.

100FF only

9642

Diagram 10.3

BAFFLE (4)

HEAT
EXCHANGER

120FF only

25 221966B

Diagram 10.4

10 Servicing

10.4 Electrode, Pilot Burner and Pilot Injector

Clean the pilot burner and electrode.

100FF Model Only. To remove the electrode release the spring
clip, see diagram 10.7.

120FF Model Only. To remove the electrode remove the
securing screw, see diagram 10.7.

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 8.3.

4306

CLEANING PLATE

50mm

380mm MIN

20mm

40mm

SEMI STIFF
NYLON BRISTLES
CLEANING BRUSH

Diagram 10.5

10.5 Operational Checks

After completing a service and before fitting the case, check
condition of the case seal and renew if necessary.

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

Light the boiler and carry out the functional checks as described
in Section 8.

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

PILOT
BURNER

PILOT
INJECTOR

ULTIMATE 100FF

SPRING
CLIP

ELECTRODE

4299

MAIN BURNER
INJECTOR

Diagram 10.6

4298

PILOT
BURNER

PILOT
INJECTOR

ULTIMATE 120FF

4299S

ELECTRODE

SECURING
SCREW

Diagram 10.7

221966B

26

11 Fault Finding

11.1 Electrical

IMPORTANT: On completion of the Service/Fault Finding task

which has required the breaking and remaking of the electrical
connections, the earth continuity, polarity and short circuit and
resistance to earth checks must be repeated using a suitable
multimeter.

Refer to diagrams 11.1 to 11.5 for the relevant fault finding and
wiring information.

Neon Indicators - An Aid to Fault Finding

THE NEON INDICATORS ARE AN AID TO FAULT FINDING ONLY. FAILURE OF ANY OF THE NEON INDICATORS DOES NOT WARRANT THE

REPLACEMENT OF AN OTHERWISE SATISFACTORY PRINTED CIRCUIT BOARD (PCB).

11.2 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 and electrical failure
the overheat device may need resetting.

Remove the control cover, see diagram 8.6 and push the reset
button on the front of the control box, see diagram 8.1.

If the cutoff operates at any other time press the reset button and
the burner should relight. If the fault persists refer to the fault
finding chart.

Is neon 1 lit?

YES

Is neon 2 lit?

YES

Is neon 3 lit?

YES

Is neon 4 lit?

YES

Is main burner operating?

YES

System satisfactory

NO

NO

NO

NO

NO

Fault with mains supply or PCB fuse

Low water pressure (sealed system),
Overheat cut off device tripped or thermostat,
overheat cut off device faulty.

- see detailed fault finding chart.

Air flow proving fault - that is fan or air pressure
switch - see detailed fault finding chart.

Ignition, pilot or flame proving fault ­see detailed fault finding chart.

Multi-functional control/harness problem ­see detailed working?
fault finding chart.

4120

NEON
INDICATORS

Diagram11.1

27 221966B

11 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 control thermostat to its maximum
setting. Also check fuses.

Is neon 1 lit?

YES

Is neon 2 lit?

NO

NO

Is there 230V~ between SL and

N and between L and N ?

YES

Is there 230V~ between K1 and N ?

YES

NO

NO

Correct power supply problem.

Check 0.2 Bar of water pressure is available at
boiler, If ok, Replace water pressure switch.

YES

Is neon 3 lit?

YES

Is there 230V~ between yellow connection on
overheat device and N ?

YES

YES

Is there 230V~
between "N/C" on thermostat and N ?

NO

Is there 230V~ between

"N/C" on air pressure switch and N ?

YES

Is there 230V~ between "C" on air pressure
switch and N ?

YES

Does fan run?

YES

Does fan Hunt?

NO

YES

Is there 230V~between "N/O" on air
pressure switch and N ?

NO

NO

NO

NO

NO

Replace fan.

YES

NO

Check overheat reset.
If satisfactory replace overheat device.

Replace thermostat.

Check yellow cable between printed circuit board
and air pressure switch.
If satisfactory replace printed circuit board.

Replace air pressure switch.

Is there 230V~ between motor connections on fan?

YES

Isolate electrical supply test fan
harness continuity.
If satisfactory replace printed circuit board.

Replace printed circuit board.

Inspect air tubes for leaks, kinks and correct fitting. If
satisfactory replace faulty air pressure switch.

NO

Is Neon 4 lit?

YES

Does main burner light?

NO

YES

System satisfactory

YES

NO

Is there a spark at pilot burner?

YES

Does pilot light?

YES

With pilot lit does spark stop?

Isolate supply. Remove plug from the
multifunctional control. Check continuity of
main solenoid between EV2 and COM.
Continuity OK?

YES

Replace multi-functional control.

NO

NO

NO

NO

Check lead continuity and inspect electrode and
lead for damage.

Check for pilot jet blockage, incorrect electrode
adjustment isolate supply. Remove plug from
multifunctional control. Check continuity of pilot
solenoid between EV1 and COM, continuity OK?

YES

Replace
multifunctional
control

Inspect electrode lead /connection
for poor contact. Check electrical supply polarity and
correct if necessary.
If satisfactory replace printed circuit board.

Replace main solenoid

M A I N T E R M I N A L S T R I P

C O N T R O L T H E R M O S T A T

Replace pilot
solenoid.

NO

Diagram 11.2

221966B

28

11 Fault Finding

bk BLACK
br BROWN
b BLUE
p PURPLE
g GREY

KEY

or ORANGE
w WHITE
r RED
y YELLOW

L

SPARK
ELECTRODE

F1

FUSE
TYPE F1 & F2
(F1A)

Pump overrun Operation for Fully

Pumped System Only

The PCB has a 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.

F2

L

P

p

b

p

CONTROL

y

N/C

rb

brbr

9

SL

br b

PUMP

br

or

w

WATER PRESSURE
SWITCH

STAT

C

y

FAN

K2

g

K1

O/H CUTOFF

or

RED

LINK

*

w

PN

N

N

b

**

b

or

N

LINK

N

Does the pump run when SL is applied ?

YES

Faulty PCB. Replace

Does pump continue to run after SL is interrupted ?

YES

Does pump stop after several minutes ?

YES

System satisfactory.

NO

NO

NO

r

bk

AIR
PRESSURE
SWITCH

y

br b

PILOT
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)

LInk fitted to bridge out water pressure switch

for open vented system.

**

AIR PRESSURE SWITCH CONNECTIONS

MAIN TERMINAL STRIP CONNECTIONS

CONTROL THERMOSTAT CONNECTIONS

PRINTED CIRCUIT BOARD CONNECTIONS

(N/O) (C)

(N/C)

bk

MAIN
SOLENOID

b

N

b

b

N

N

N

N

FOR FULLY PUMPED OPEN VENTED
OR SEALED WATER SYSTEMS ONLY

Diagram 11.3

FULLY PUMPED OPEN VENTED
OR SEALED WATER SYSTEM

29 221966B

Diagram 11.4

11 Fault Finding

SEQUENCE
BOARD

WATER
PRESSURE
SWITCH

p

g

y

r

C

NC

NO

bk

g/y

b

r

AIR
PRESSURE
SWITCH

ELECTRODE

FAN

KEY

b - BLUE
bk - BLACK
br - BROWN
g/y - GREEN/

YELLOW

r - RED

MULTI-FUNCTIONAL
CONTROL

y - YELLOW
w - WHITE
p - PURPLE
g - GREY

PLUG

9075

NC

3 PLUGS

y

CHASSIS

CHASSIS EARTH

g/y

FUSES F1 &
F2 (F1A)

b

or

p

br

g/y

g

p

g/y

w

K2
K1

g/y

p

b

PN

br

g/y

SL

L

N

br

P

b

9

r

br

b

g/y

EARTH

NOTE:-

Bridge out Water Pressure Switch
between K1 & K2 if using open vented
system

E

CIRCULATION

L

PUMP

N

✽ See Note

L

230~50Hz

N

PERMANENT
MAINS

E

SUPPLY
FUSED
AT 3-AMP

w

y

C

OVERHEAT

w

SWITCH CONTROL,
TIME SWITCH,
PROGRAMMER ETC.
(if fitted)

CUTOFF

CONTROL
THERMOSTAT

FULLY PUMPED OPEN VENTED OR
SEALED WATER SYSTEM

221966B

✽ 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)

Diagram 11.5

30

12 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.

12.1 Access

Gain access as Section 10.1.

12.2 Control Thermostat - diagram 12.1 and

12.2

Remove and support the electrical control box, refer to Section

7.1.

Remove the control knob. Remove the electrical connections
from the control thermostat body.

Release the control thermostat body be 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 the plastic
retaining clip then remove it from the split grommet. Release the
capillary from its clips. Remove the thermostat complete from
the boiler.

Reassembly NOTE: When refitting the thermostat make sure
that the thermostat phial is covered with heat sink compound
then fully inserted into the phial pocket and that the capillary is
within the gland seal, see diagram 12.2. Remake the electrical
connections. There must be no kinks or sharp bends in the
capillary.

CONTROL

9076

THERMOSTAT

SHAKEPROOF
WASHERS AND
SCREWS

CONTROL
KNOB

ELECTRICAL

CONNECTIONS

YELLOW C &

NC

SPLIT
GROMMET

RETAINING
CLIP

12.3 Overheat Cutoff Device - diagram 12.1,

12.2 and 12.2A

Remove and support the electrical control box, refer to Section

7.1.

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.

Remove the split pin and then the phial.

When refitting use the heat sink compound supplied.

LOCKNUT

ELECTRICAL
CONNECTIONS

Diagram 12.1

31 221966B

12 Replacement of Parts

12.4 Control Board (PCB) - diagram 12.2A

Release the control box, refer to Section 7.1.

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 11.5.

12.5 Pilot Burner and Pilot Injector

Proceed as Section 10.2 and 10.4.

12.6 Electrode

Proceed as Section 8.3 and 8.5.

Gain access as Section 7 to remove lead from control box.

4301

PHIAL
POCKET

SPLIT
PIN

OVERHEAT
CUTOFF
DEVICE
PHIAL

12.7 Multifunctional Control - diagram 10.3

Disconnect the pilot supply by unscrewing the tubing nut at the
multifunctional control.

120FF ONLY. Take care as there is a restrictor in the pilot pipe.

Disconnect the electrical plug.

Support the multifunctional control, remove the four extended
screws from the flanged connections at the left and right hand
side.

Remove and discard the original “O” rings from the flanged
connection and fit the new “O” rings 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
I.S.813 "Domestic Gas Installations".

12.8 Solenoid - diagram 12.3

Remove the electrical plugs from the multifunctional control.
Remove the securing screw and then the solenoid assembly.

ELECTRICAL PLUGS

5756

CHASSIS
EARTH
CONNECTION

EARTH
CONNECTION

MAIN
TERMINAL
STRIP

SECURING
SCREW (2)

CONTROL
THERMOSTAT
ELECTRICAL
CONNECTION
NO.6
"YELLOW"
CABLE

OVERHEAT
CUTOFF
ELECTRICAL
CONNECTION
"WHITE"
CABLE

IGNITION
LEAD

SUPPORT
POST (4)

4090

SPLIT
PIN

RETAINING
CLIP

221966B

THERMOSTAT
PHIAL

Diagram 12.2

32

PLASTIC
RETAINING
CLIP

ELECTRICAL
PLUGS

ELECTRICAL
CONNECTION
BLUE CABLE "SL"

ELECTRICAL
CONNECTION
BLUE CABLE "N"

Diagram 12.2A

12 Replacement of Parts

12.9 Main Burner

Remove the main burner as Section 10.2.

12.10 Main Injector

Remove the main burner as Section 10.2.

Remove the main injector as Section 10.3.

12.11 Insulation - diagram 12.4

Combustion Chamber Front

Remove the retaining screw then the insulation.

Sides

Slide the insulation out.

12.12 Viewing Window - diagram 12.5

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 12.5. Ensure no air bubbles are trapped
underneath the foil.

12.13 Air Pressure Switch - diagram 12.6

Release the control box as Section 7.1

Remove the pressure tubes and the electrical connections from
the PCB, release the screws and remove the switch.

When fitting the replacement make sure that the plastic tubes
and electrical connections are made as shown in diagram 11.5
and 12.6.

SECURING SCREW

4303

FRONT
INSULATION

SIDE INSULATION

RESTRICTOR
(120FF Only)

PILOT PIPE
TUBING NUT

SOLENOIDS

ELECTRICAL
PLUG

EXTENDED
SCREW
(8 off)

SECURING
SCREW

Diagram 12.3

4302

MICA WINDOW

SELF ADHESIVE
ALUMINIUM FOIL
GASKET

Diagram 12.4

7907

OPENING
(INSIDE FACE
OF THE BOILER
FRONT COVER)

PEEL OFF
BACKING
PAPER

Diagram 12.5

33 221966B

12 Replacement of Parts

12.14 Fan - diagram 5.3

Remove the electrical connections and disconnect the air
pressure tubes.

Remove the fan assembly securing screws.

Make sure that the earth connection is remade onto the new fan
assembly.

The polarity of the other connections is not important.

9077

AIR PRESSURE
SWITCH TUBES

SECURING
SCREWS

CLEAR

RED

12.15 Water Pressure Switch - Sealed Water
System Only

Release the water pressure and drain, refer to Section 3.

Disconnect the electrical connections at the microswitch, see
diagram 12.7.

Remove pressure switch.

On assembly, use new “O” ring, secure the water pressure
switch with locknut in the orientation shown as diagram 12.7.

Make up water loss and pressurise system, refer to
“Commissioning”.

4304

WATER PRESSURE
SWITCH

AIR

PRESSURE

ELECTRICAL
CONNECTIONS

CONTROL

SWITCH

BOX

Diagram 12.6

13 Spare Parts

13.1 Part Identification

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

ELECTRICAL
CONNECTIONS

GREY

PURPLE

Diagram 12.7

13.2 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 at the bottom right hand side of case.

If ordering from British Gas also quote the GC number of the
appliance from the data label and the GC number of the spare
part, from the list.

221966B

34

13 Spare Parts

Key No Part No Description GC Part No

1 800442 Multifunctional control 278 021
2 208040 “O” ring 334 592
3 205727 Injector - 100FF 278 197
3 205726 Injector - 120FF 278 196
4 203432 Pilot burner - 100FF 278 023
4 203434 Pilot burner - 120FF E00 998
5 2000801236 Mica Glass *********
6 2000800529 Fan assembly - 100FF 278 194
6 2000800532 Fan assembly - 120FF 278 185
7 202626 Spark electrode and lead - 100FF 313 998
7 202629 Spark electrode and lead - 120FF 278 238
8 K3580 Clip - electrode 390 983
9 800850 Thermostat - control *********
10 202232 Air pressure switch - 100FF 278 239
10 202201 Air pressure switch - 120FF 313 992
11 800275 Control knob 313 609
12 2000800656 Water pressure switch *********
13 204212 “O” ring 281 343
14 202015 Fuse 334 750
15 900847 Control board PCB *********
16 800272 Overheat safety cutoff 313 606

9042

5

11

4 (120FF)

7
(120FF)

4 (100FF)

7
(100FF)

6 (100FF
ILLUSTRATED)

3
(100FF
ILLUSTRATED)

2

9

1

8

10
(100FF ILLUSTRATED)

14

13

15

12

16

Diagram 13.1

35 221966B

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

221966B

36