Glow-worm Ultimate 50FF User Manual

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Instructions for Use

Installation and Servicing

To be left with the user

50FF

G.C. No. 41 047 55

2000225232A.10.04

4098

Fanned Flue Boiler

BS 6332 BS 5258

This is a Cat II

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.

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

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

Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:

Appliance

2H3P

Guarantee Registration

to offer our customers' a Comprehensive First Year Guarantee.

Service number 01773 828100.

✔

All replacement parts

❏

✔

All labour charges

❏

All call-out charges

✔

❏

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0800 073 2142

Glow-worm,

Tel: (01773) 828100

Fax: (01773) 828070

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: (01773) 824141 Fax: (01773) 820569

www.glow-worm.co.uk

Important Information

TESTING AND CERTIFICATION

This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Glow-worm.

Any alteration not approved by Glow-worm, could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.

CE MARK

This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels.

Type test for purposes of Regulatioon 5 certified by: Notified body 0086.

Product/production certified by: Notified body 0086.

The CE mark on this appliance shows compliance with:

1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.

2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use 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.

Ceramic Fibre/Insulation Pads.

These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation of the eyes or severe irritation to the skin seek medical attention.

Thermostats

These contain very small amounts of xylene in the sealed phial and capillary. If broken, under normal circumstances the fluid does not cause a problem, but in case of skin contact, wash with cold water. If swallowed drink plenty of water and seek medical attention.

Cut-off Devices

These contain activated charcoal and a very small amount of chlorodifluormethane in the sealed phial and capillary. If broken, under normal circumstances the fluid does not cause a problem. If there is irritation to the eyes or skin then seek medical attention.

SPARE PARTS

REMEMBER: When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance

specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

Introduction 3 Lighting the Boiler 4

General Data 1 5 Flue & Ventilation 2 8 Water Systems 3 9 Flue and Appliance Preparation 4 13 Boiler Installation 5 18 Commissioning 6 22 Instructions to User 7 25

SERVICING

INSTRUCTIONS

2000225232B

Servicing 8 25 Fault Finding 9 27 Replacement Parts 10 33 Spare Parts 11 38

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

If your boiler has been converted to use L.P.G. Propane the following applies:

NOTE: Propane cylinders are under pressure and should never be stored or used indoors residentially.

They should only be kept outside.

Under no circumstances should L.P.G. Propane cylinders be fitted or stored in basement areas or boiler houses.

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.

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.

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.

CONTROLS COVER

4140

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.

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.

VIEWING WINDOW

10264

SETTING POINT

RESET BUTTON

CONTROL THERMOSTAT KNOB

DATA & SERIAL NUMBER LABEL

GAS SERVICE COCK (Shown Off)

Diagram 1

2000225232B

Instructions for Use

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

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.

500mm

Additional clearances may be required for installation

100mm

65mm

2000225232B

FRONT

VIEW

(24/0.20mm).

SIDE OR REAR FLUE 5mm

5mm

6mm6mm

Diagram 2

0081M

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

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

C (180oF), see diagram 1.

The boiler lighting operation is now automatic as follows.

The fan operates, followed by an ignition spark until the pilot is lit. When the pilot is alight the ignition system switches off and the main burner lights. The flames can be seen through the viewing window, see diagram 1.

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

If the boiler is switched OFF, by hand, wait at least 30 seconds before switching on again.

When the boiler switches off, both the pilot and main burner go out.

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

Refit the controls cover.

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

To Turn the Boiler Off

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

1 General Data

SIDE ELEVATION FRONT ELEVATION

300

6758

FLOW

GRAVITY

RETURN

PUMPED

WATER CONNECTIONS 22mm COPPER PIPE

GAS CONNECTIONS

/2 (1/2 in. BSPT)

GRAVITY

RETURN

PUMPED

FLOW

All dimensions are given in millimetres

(except as noted)

146

360G139

700K574

130

IMPORTANT NOTICE

This boiler is for use on Natural Gas (G20) as distributed in the United Kingdom and Ireland but may be converted for use on G31 gas (Propane L.P.G.) with an available conversion kit. Kit No. 2000462100. 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 be provided by gravity or pumped circulation.

Wherever possible, all materials, appliances and components used shall comply with the requirements of applicable British Standards.

Where no British Standard exists, materials and equipment should be fit for their purpose and of suitable quality and workmanship.

Refer to Manual Handling Operations, 1992 regulations.

Sheet Metal Parts

WARNING: When installing or servicing this boiler care should

be taken when handling sheet metal parts, to avoid any possibility of personal injury.

1.1 Statutory Requirements

In GB the installation of the boiler must be carried out by a competent person as described in the following regulations:

The manufacturer’s instructions supplied.

The Gas Safety (Installation and Use) Regulations.

The appropriate Buildings Regulations either The Building Regulations, The Building Regulations (Scotland),The Building Regulations (Northern Ireland).

The Water Fittings Regulations or Water byelaws in Scotland.

The Health and Safety at Work Act, Control of Substances

Diagram 1.1

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 and diagram 1.1

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

The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is 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.

1.3 Range Rating

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

See diagram 1.2 for the ratings and settings.

2000225232B

1 General Data

DATA TABLE 1.

TOTAL DRY WEIGHT

43.4kg (96b)

(Including Terminal)

LIFT WEIGHT

WATER CONTENT

GAS CONNECTION

ELECTRICITY RATING

WATER CONNECTION

ELECTRICITY SUPPLY

DATA LABEL

4x22mm copper pipes from

Bottom right hand side of case

37.7kg (83lb)

2.35L (0.52gal)

/2 in.

56W

Internal fuse Type F1A

top of case

230V~50Hz, fused 3A

Min. Medium Max.

APPROX. GAS RATE

1.38

49.0

1.51

53.0

1.67

59.0

1.4 B.S.I. Certification

This boiler is certificated to the current issue of British Standard 6332 Part 1, invoking the current issue of BS5258 Part 1 for performance and safety. It is, therefore, important that no alteration is made to this boiler without permission, in writing, from Glow-worm.

Any alteration that is not approved by Glow-worm, could invalidate the B.S.I. Certification of the boiler, warranty and could also infringe the current issue of the Statutory Requirements.

1.5 Gas Supply

The gas installation shall be in accordance with the relevant standards.

In GB this is BS6891.

In IE this is the current edition of 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 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".

6807

Connection of the boiler and system controls to the mains supply must be through a common isolator and must be fused 3A, maximum. This method of connection must be by a fused double pole isolating switch, with a minimum contact separation of 3mm on both poles. The switch should be readily accessible and preferably adjacent to the appliance. It should supply the appliance only and be easily identifiable as so doing.

Alternatively, an unswitched shuttered socket outlet and 3A fused 3 pin plug, both to the current issue of BS1363 may be used provided that they are not used in a room containing a bath or shower.

Wiring to the boiler must be to the current issue of BS6500 Table 16, not less than 0.75mm

(24/0.20mm).

1.7 Contents of Packaging

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

1.8 Water System

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

1.9 Drain

System

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

Draining taps should be to the current issue of BS2879.

Boiler

A draining point is fitted at the bottom right hand side of the heat exchanger.

Cover the controls to avoid water damage.

If required remove the combustion chamber front cover to improve access.

1.10 Safety Valve

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

9910

Diagram 1.2

2000225232B

1 General Data

1.11 Location

This boiler is not suitable for outdoor installation.

This boiler is suitable for installation in bathroom zones 2 and 3.

The boiler may be installed in any room, although particular attention is drawn to the requirements of BS7671 with respect to the installation of a boiler in a room containing a bath or shower. Any electrical switch should be so positioned that it cannot be touched by a person using the bath or shower. The electrical provisions of the Building Standards (Scotland) Regulations apply to such installations in Scotland.

In GB this is the current 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 1.3.

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

Additional clearances may be required for installation.

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

At least a minimum clearance of 500mm must be left in front of the boiler for servicing, see diagram 1.3.

0081M

500mm

Additional clearances may be required for installation

1.13 Room Ventilation

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

1.14 Boilers in a Compartment

Where the installation of the boiler will be in an unusual position, special requirements are needed, the current issue of BS6798 gives detailed guidance on these requirements.

A compartment used to enclose the boiler must be designed and constructed specifically for this purpose. An existing cupboard or compartment modified for the purpose may be used. Details of essential requirements for cupboard or compartment design are given in the current issue of BS6798.

The doorway opening should be of sufficient size to allow for easy removal of the boiler.

Where the boiler is fitted in a cupboard or compartment, permanent high and low level ventilation must be provided. The minimum ventilation areas required are given in Table 2.

1.15 Timber Frame Building

If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. 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 aroom 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.

1.17 Anti-theft Kits

Anti-theft kits are available for these appliances, contact Glow-worm. for further information.

VIEW

5mm

6mm6mm

SIDE OR REAR FLUE 5mm

100mm

FRONT

65mm

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

Diagram 1.3

TABLE 2. COMPARTMENT AIR VENTS

VENTILATION REQUIREMENTS

VENTILATION FROM ROOM OR SPACE

VENTILATION FROM OUTSIDE

HIGH LEVEL VENT AREA

1658325

12.5

LOW LEVEL VENT AREA

1658325

12.5

2000225232B

6760

2 Flue and Ventilation

NOTE: Detailed recommendations for flues are given in the

current issue of BS5440 Part 1.

2.1 Terminal Position

The minimum acceptable siting dimensions for the terminal from obstruction, other terminals and ventilation openings are shown in 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.

B,C

Under Car Port etc.

H,I

MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION

B,C

0103M

MINIMUM

SPACING

in mm

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 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 75

F FROM EXTERNAL CORNERS 300

G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300

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

2000225232B

0161M

Diagram 2.1

3 Water Systems

1000

750

500

250

19.1

051015 20 25 30

Flow rate (litres/minute)

Water pressure loss

(mm head of water)

0088

The insertion point indicates the flow rate required to achieve 11°C temperature difference

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.

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 (20oF), between the flow and return, with the boiler 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 is usually unnecessary on systems using a 3 port diverter valve since one port will remain in the open position at all times. This allows satisfactory operation of the pump overrun.

However if thermostatic radiator valves are fitted to all radiators or two port valves are used a bypass is required.

The bypass connection must be at least 2 metres away from the boiler.

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

3.4 Water System

For an open vented system the boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern fitted at a maximum height of 27metres above the boiler.

The cold feed must be 15mm minimum size.

It is important that the relative positions of the pump, cold feed and open vent are as shown in diagram 3.2.

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

3.5 Domestic Hot Water System

General - All domestic hot water circuits, connections, fittings

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

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

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.

C between the

PRESSURE LOSS OF BOILER

Diagram 3.1

3.6 Cylinder

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

3.7 Gravity Domestic Hot Water with Pumped Heating

Important: If domestic hot water is to be provided by a gravity circulation to the cylinder the blanked off connections must be opened and used, using 22x28mm connections, see diagram

3.3.

3.8 Fully Pumped Heating and Domestic Hot Water

The connections for this type of system MUST be as shown in diagram 3.2 and 3.4.

3.9 Inhibitor

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 radiators, then thoroughly cleaning out before installing the boiler whether or not adding an inhibitor.

3.10 Sealed Water Systems

The installation should comply with the appropriate requirements of the current issue of BS4814, BS5449, BS6759, BS6798 and BS7074 Part 1 and 2, see diagram 3.5 for a suggested layout.

3.11 Safety Valve

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

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

2000225232B

3 Water Systems

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

22mm VENT

450mm

(MIN.) MIN. HEIGHT

15mm (MINIMUM) COLD FEED

FEED AND EXPANSION CISTERN

1150mm

RETURN

MIN.

CYLINDER

PUMP

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

150mm MAX.

FLOW

of the boiler.

RET.

BOILER

IF REQUIRED 15mm (MINIMUM) BY-PASS WITH LOCKSHIELD VALVE

Diagram 3.2

6455

FLOW

HEATING

4107

1metre Min.

27 metres

Max.

FLOW

RETURN

22mm PIPE

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

INDIRECT

IF REQUIRED BYPASS 15mm MIN WITH LOCKSHIELD VALVE

CYLINDER

ALTERNATIVE SYSTEM CONTROL VALVES

PUMP

6461

HEATING SYSTEM

4124

1m MIN. 27m Max.

28mm

VIEWED FROM FRONT

PUMPED

RETURN

22mm VENT

15mm COLD FEED

INDIRECT CYLINDER (Shown with recommended thermostat and valve).

PUMP

REFER TO BS 5546

PUMPED

FLOW

HEATING SYSTEM

Diagram 3.3

0090M

FULLY PUMPED CIRCULATION SYSTEM (DIAGRAMMATIC)

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

INDIRECT CYLINDER

1metre Min.

27 metres

Max.

FULLY PUMPED CIRCULATION BYPASS (DIAGRAMMATIC)

IF REQUIRED BYPASS 15mm MIN WITH LOCKSHIELD VALVE

PUMP

6456

HEATING SYSTEM

ALTERNATIVE SYSTEM CONTROL VALVES

Diagram 3.4

2000225232B

3 Water Systems

3.12 Expansion Vessel

A diaphragm type expansion vessel, conforming to the current issue of BS4814 (see also BS7074 Part 1 and 2) must be connected at a point close to the inlet side of the circulating pump, see diagram 3.5 unless laid down differently by the manufacturer.

The expansion vessel volume depends upon the total water system volume and the initial system design pressure. For any system an accurate calculation of vessel size is given in the current issue of BS5449 and BS7074 Part 1, for IE refer to the current edition of I.S.813 "Domestic Gas Installations".

Example: For an initial system design pressure of 0.7bar the minimum total vessel volume required is 0.063xTotal System volume.

NOTE: A higher initial design pressure requires a larger volume expansion vessel.

The charge pressure must not be less than the static head of the system, that is, the height of the highest point of the system above the expansion vessel.

The water content of the boiler is given in Data Table 1.

3.13 Pressure Gauge

A pressure gauge with a set pointer and covering at least the range of 0 to 4bar (0 to 60lb/in2) shall be permanently fitted to the system in a position where it can be seen when filling the system.

3.14 Domestic Hot Water Cylinder

SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE.

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

3.15 Domestic Hot Water System - Unvented

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

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

(Make-up alternatives)

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

NON-RETURN VALVE

HEATING

CIRCUIT

AUTO AIR VENT

FLOW

RETURN

DRAIN COCK

BOILER

IF REQUIRED 15mm (min) BY-PASS WITH LOCKSHIELD VALVE

SAFETY VALVE

AIR RELEASE POINT

FILLING POINT

CIRCULATING PUMP

PRESSURE GAUGE

EXPANSION VESSEL

6457

Diagram 3.5

2000225232B

3 Water Systems

3.16 Filling a Sealed Water System

Provision for filling the system at low level must be made. Three methods are shown in diagram 3.6. There must be no permanent connection to the mains water supply, even through a nonreturn valve.

3.17 Water Makeup

Provision must be made for replacing water lost from the system. A make up vessel mounted above the highest point of the system and connected through a non-return valve to the system on the return side of either the hot water cylinder or heating system, see diagram 3.5.

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

METHOD 1

TEMPORARY HOSE

SUPPLY PIPE

METHOD 2

TEMPORARY HOSE

SUPPLY PIPE

METHOD 3

CISTERN

HOSE UNIONS

SUPPLY STOP VALVE

DOUBLE CHECK VALVE ASSEMBLY

HOSE UNIONS

SUPPLY STOP VALVE

OVERFLOW

SERVICING VALVE

COMBINED CHECK VALVE AND VACUUM BREAKER

SERVICING VALVE

PRESSURE REDUCING VALVE

0051M

HEATING SYSTEM

SUPPLY STOP VALVE

SUPPLY PIPE

HOSE UNIONS

DOUBLE CHECK VALVE ASSEMBLY

Diagram 3.6

2000225232B

4 Flue and Appliance Preparation

4.1 Unpacking

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

4.2 Flue Position and Length

Determine flue application, length and terminal position before starting.

Refer to diagram 4.2 or 4.3.

If you are using a Flue Bend or a Vertical Flue Kit, please follow the instructions supplied with that kit.

To make a neat finish to the flue outlet a flue collar kit, part No.443286, with instructions, is available.

NOTE: the use of this collar will mean that the flue lengths will need to be altered, full instructions are given in the kit.

NOTE: If required, an optional Wall Liner Kit, Part No. 900862, is available, complete with fixing instructions.

6827

Standard Flue terminal illustrated.

WALL TEMPLATE

MOUNTING BRACKET

LOOSE ITEMS PACK

CARTON TOP

INSTRUCTIONS

BOILER

4791

REAR FLUE LENGTHS

Distance R = Wall thickness

STD. 75mm to 505mm

1M 75mm to 1015mm

2M 75mm to 2015mm

3M 75mm to 2995mm

Diagram 4.2

6828

Diagram 4.1

Standard Flue terminal illustrated.

SIDE FLUE LENGTHS

Distance S = External wall face to boiler case

STD. 81mm to 513mm

1M 81mm to 1023mm

2M 81mm to 2023mm

3M 81mm to 3003mm

Diagram 4.3

2000225232B

4 Flue and Appliance Preparation

SIDE FLUE

REAR FLUE

75mm

115mm MINIMUM HOLE

0098M

BOILER CENTRE LINE

FLUE CENTRE LINE

14mm

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.

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.

4.4 Rear and Side Flue Application

Select the boiler location and flue application, with due regard to the terminal position.

Take the template from the boiler pack and temporarily position it on the wall, making sure that the minimum clearances are maintained, see diagram 1.2.

For a rear flue mark the position of the flue as diagram 4.4.

For a side flue, extend the centre line horizontally left or right to the corner of the adjacent surface where the flue is required to exit to outside. Mark the position of the centre of the flue and boiler, as diagram 4.4.

4.5 Flue Hole Cutting

Having marked out the flue centre cut a hole for the flue using, preferably, a 115mm minimum core drill.

/16 in dia.

PLUG

7 dia.

NO. 12x2in

TEMPLATE

BOILER CENTRELINE

TOP BOILER MOUNTING HOLES

FLUE CENTRELINE

MOUNTING BRACKET FIXING POINTS

BOILER CENTRELINE

5mm

FLUE CENTRELINE

BOILER MOUNTING BRACKET

Diagram 4.4

4096

2000225232B

7 dia.

/16 in dia.

PLUG

NO. 12x2in

Diagram 4.5

4 Flue and Appliance Preparation

4.6 Wall Mounting Bracket

Reposition the template, making sure of dimensional alignment with the flue hole.

Mark the boiler fixing points and mounting bracket position, see diagram 4.5.

Drill holes and plug, to suit No.12x2in wood screws, fit the screws allowing sufficient clearance, about 5mm, to accept the swing brackets, see diagram 4.5.

Secure the mounting bracket to the wall with No.12x2in wood screws and plugs, see diagram 4.5.

4.7 Flue Duct

Mark the duct to the length required, this length allows for expansion, see diagram 4.6 for rear flue and diagram 4.7 for side flue, then cut square and remove any burrs.

4.8 Air Duct/Terminal

Mark the duct length, see diagram 4.8 for rear flue and diagram

4.9 for side flue, then cut square and remove any burrs.

6831

T MINUS 188mm

BOILER

CENTRE

LINE

6833

FLUE

DUCT

Diagram 4.7

6829

LONG FLUE

TERMINAL

STANDARD FLUE TERMINAL

Q PLUS 5mm

Diagram 4.6

Diagram 4.8

2000225232B

4 Flue and Appliance Preparation

4.9 Air Duct/Terminal and Flue Duct Assembly

Locate the flue duct into the air duct/terminal, see diagram 4.10.

Take the flue manifold from the loose items pack together with the sealant. Place the sealant onto the flue manifold.

Fully locate the flue manifold in to the air duct/terminal and flue duct assembly as shown in diagram 4.10, make sure the correct alignment of the “Top”s.

Drill two 3mm diameter holes through the air duct/terminal to the flue manifold secure with the two self tapping screws supplied in the loose items pack.

It should now not be possible to remove the manifold.

4.10 Rear Fitting

Fit the self adhesive foam seal provided in the flue pack around the air duct/terminal at the position shown in diagram 4.13.

4.11 Side Fitting

Fit the self adhesive foam seal around the air duct/terminal such that, when installed, the seal will be within the wall, see diagram

4.14.

If dimension "A" is greater than 75mm from the wall, the self adhesive foam seal can be dispensed with, and the area around the flue made good in the normal way, see diagram 4.14.

Important: If the wall liner kit is used the self adhesive foam seal included in the wall liner kit must be used in place of the one supplied with the flue pack, see diagram 4.11 for position of self adhesive seal.

4616

6830

AIR DUCT/TERMINAL AND FLUE DUCT ASSEMBLY

LONG FLUE

TERMINAL

STANDARD FLUE TERMINAL

BOILER

CENTRE

LINE

2000225232B

Diagram 4.9

Diagram 4.10

4 Flue and Appliance Preparation

4.12 Flue Assembly - Installation

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

On limited access installations push the flue assembly into the hole such that it is within the wall and does not stick out into the room, see diagram 4.12. Do not push the flue assembly too far into the hole as it has to be pulled back into the boiler and secured.

4.13 Internal Access Flue

If access to the outside wall is not practical, the flue system can be installed from inside. Use of the optional wall liner kit is required.

4082

GASKET

(PRE-ATTACHED)

Diagram 4.12

WITH WALL LINER KIT ONLY

FOAM

SEAL

10mm

WALL THICKNESSUP TO 300mm

FOAM

SEAL

FOAM

SEAL

6832

REAR FITTING

Diagram 4.13

6930

"A"

6931

WALL THICKNESSOVER 300mm

Q-25mm

Diagram 4.11

SIDE FITTING

FOAM

SEAL

Diagram 4.14

2000225232B

5 Boiler Installation

5.1 Boiler Preparation

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

Remove the front cover by undoing the wing nut, nut and washer, lift the front cover off, see diagram 5.1.

Place front cover on one side until required.

Fit suitable compression fittings to the required tappings on the boiler.

NOTE: For gravity domestic hot water use 22x28mm connections on the stubs, see diagram 5.2.

5.2 Mounting the Boiler

As necessary, fit the blanking plate, see diagram 5.5.

Now make sure that the top, swing brackets are UPRIGHT.

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

Lift the boiler into position, hooking over the mounting bracket.

Swing the brackets over the two screws at the top. Hold the swing bracket(s) in place whilst tightening the screw(s) onto it, see diagram 5.3.

Remove the blue and red electrical connections from the fan, see diagram 5.4.

Break the air pressure switch tube connections, see diagram

5.4.

Remove the fan assembly by removing the screws at the front, slackening the screws at the rear and sliding it out, see diagram

5.4.

Taking care not to damage the gasket, secure the flue assembly to the boiler using the previously fitted dogpoint screws noting that these are keyhole fixings, see diagram 5.5.

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

For a side outlet cut the fan duct extension to the length required, see diagram 5.6.

Remove any burrs and fit as diagram 5.6.

Fit the fan duct extension to the elbow and assemble to the fan as shown in diagram 5.6.

Do not secure at this point with the screw.

Position the fan assembly and engage the fan duct extension over the flue manifold. Make sure, by pushing the flue duct extension that a secure seal is made.

Mark the final position of the fan duct extension through the screw hole on the elbow, remove the assembly and secure with the screw as diagram 5.6.

Secure the elbow to the fan outlet with the Jubilee clip.

For rear outlet cut and fit the fan duct extension, as diagram 5.6. Secure with the Jubilee clip.

Fit fan assembly by engaging the fan duct extension over the flue manifold spigot, see diagram 5.7.

Secure the fan assembly with the screws previously slackened and removed.

Reconnect the blue and red electrical connections to the fan, the polarity of the connections is not important.

Reconnect the air pressure switch tubes as shown in diagram

5.4.

WING NUT

4133

22mm GRAVITY DOMESTIC HOT WATER STUB

✽

22mm HEATING RETURN

22x28 GRAVITY DOMESTIC CONNECTION

✽ NOTE: When cutting leave sufficient length for fittings

CONTROLS

4115

COVER

FRONT COVER

SECURING NUT

SHAKEPROOF WASHER

Diagram 5.1

22mm HEATING FLOW

Diagram 5.2

2000225232B

5 Boiler Installation

5.3 Water Circulation System

Complete the water connections to the boiler.

Fill, vent and flush the system.

Check for any water leaks and put right.

5.4 Safety Valve Discharge

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

5.5 Gas Connection

Make the gas connection to the Rc1/2in gas service cock, see diagram 6.1.

Check for leaks using a suitable leak detection fluid.

The whole of the gas installation, including the meter, should be inspected, tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition of I.S. 813 "Domestic Gas Installations".

5.6 Control Box Removal

Remove the electrical control box securing screws, see diagram

5.8. Slide the box forwards and release, hook it onto the lip bracket at the front, see diagram 5.8.

5.7 Electrical Connection

WARNING: This boiler must be earthed.

Take care not to damage any internal wiring and capillaries.

Take the plastic cable retaining clip, from the loose items pack, peel off the backing paper and position it in a suitable place to secure the incoming cable.

Using heat resistant (85

0.2mm) to the current issue of BS6500 Table 16 and of a suitable length, thread through the cable clamps, secure into the plastic clips and connect to appropriate terminals, see relevant diagram 5.9 or 5.10.

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

The mains cable outer insulation must not be cut back external to the cable clamp.

Make sure the cable is suitably secured.

When making connections, make sure that the earth conductor is made of a greater length than the current carrying conductors, so that if the cable is strained the earth conductor would be the last to become disconnected.

C) cable of at least 0.75mm2 (24/

5.8 Gravity Domestic Hot Water Systems

Fit the yellow link cable, supplied in the fittings pack, between terminal K1 and K2, see diagram 5.9.

5.9 Pump Connection

FULLY PUMPED

The pump must be connected directly to the control box, as shown in diagram 5.10 threading the cable through the cable clamp in the side of the control box.

PUMPED HEATING AND GRAVITY DOMESTIC HOT WATER

The pump must be wired into the central heating remote controls.

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

ELECTRICAL CONNECTIONS

AIR PRESSURE TUBES

CLEAR

RED

4084

SWING BRACKET

SECURING SCREWS (2)

NOTE:

PIPES REMOVED FOR CLARITY

5mm

MOUNTING BRACKET

Diagram 5.3

0167(a)M

REAR SECURING SCREW (2) (SLACKEN but do not remove)

GASKET

SECURING SCREW (2)

Diagram 5.4

2000225232B

5 Boiler Installation

REAR

SIDE LEFT

FAN DUCT EXTENSION

JUBILEE CLIP

SIDE RIGHT

FAN

DUCT

EXTENSION

2.5mm dia.drill

LEFT

RIGHT

REAR

VERTICAL

SCREW

(2)

4618

4617

4134

NUT (3)

GASKET

FLUE ELBOW

BLANKING PLATE

Cutting 'MARK' lengths. Lefthand flue does not require cutting.

(REAR FLUE OUTLET ILLUSTRATED)

FLUE MANIFOLD SPIGOT

FAN DUCT EXTENSION

Diagram 5.6

4106

2000225232B

LOCATION LUG

KEYHOLE

Diagram 5.5

Diagram 5.7

5 Boiler Installation

5.10 External Controls

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

GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING, SEE DIAGRAM 5.9.

FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS, SEE DIAGRAM 5.10.

5.11 Testing

Checks to ensure electrical safety must be carried out by a competent person.

After installation of the system, preliminary electrical system checks as below should be carried out:-

1. Test insulation resistance to earth.

2. Test earth continuity and short circuit of all cables.

3. Test the polarity of the mains.

The installer is requested to advise and give guidance to the user on the controls scheme used with the boiler.

LIP BRACKET

SECURING SCREWS (2)

Diagram 5.8

5739

GRAVITY DOMESTIC HOT WATER AND

CABLE CLAMPS

PUMPED CENTRAL HEATING

Make sure that the red link is connected between terminals SL and 9 on the terminal block, as diagram 5.9 and 9.6.

FULLY PUMPED OPEN VENTED

CABLE CLAMPS

OR SEALED WATER SYSTEM

Any external controls must only be wired to interrupt the red link between terminals SL and 9. See relevant wiring diagrams for either, a sealed water system or fully pumped open vented, diagram

5.10 and 9.7.

MAINS CABLE

PUMP CABLE

MAINS CABLE

g/y

L N

g/y

REMOVE YELLOW LINK

br b

RED LINK

br b

g/y

CHASSIS EARTH

Yellow link fitted to bridge out the overheat cutoff

Pump must be wired into central heating system remote controls and NOT to control box

Ensure RED LINK connected between 9 and SL.

L N

230~50Hz MAINS SUPPLY FUSED AT 3-AMP

Diagram 5.9

CHASSIS EARTH

SWITCH CONTROL, TIME SWITCH, PROGRAMMER ETC. (when fitted remove red link)

CIRCULATON

PUMP

230~50Hz MAINS

SUPPLY

FUSED AT 3-AMP

Diagram 5.10

2000225232B

6 Commissioning

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

6.1 All Systems

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

Do not operate the boiler wthout water.

Make sure that the system has been thoroughly flushed out with cold water without the pump in place.

Refit the pump, fill the system with water, ensuring that all the air is properly vented from the system and pump.

Before operating the boiler check that all external controls are calling for heat.

6.2 Sealed Water Systems Only

Flush the whole system with cold water without the pump in place. Refit the pump and fill until the pressure gauge registers

2.7bar (40lbf/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/in 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.

) of the preset pressure. Where

SETTING POINT

OVERHEAT RESET BUTTON

CONTROL THERMOSTAT KNOB

GAS SERVICE COCK (SHOWN OFF)

COVER SCREW

Diagram 6.1

GAS PRESSURE ADJUSTMENT SCREW

4085

4108

6.3 Initial Lighting and Testing

CAUTION: This work must be carried out by a competent person, in accordance with the current issue of BS6798.

Make sure that all naked lights and cigarettes are out.

Identify the controls by reference to diagram 6.1.

Check that the boiler is isolated from the electrical supply.

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

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

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

Disconnect the ignition lead from the PCB,see diagram 5.9.

Remove the combustion chamber front, see diagram 6.3.

WARNING: The fan operates on mains voltage, terminals will become live.

Turn the electrical supply on and check that all remote controls are calling for heat.

Check that the pump is circulating water through the system.

To complete the test it is necessary to operate the boiler without its case, but UNDER ALL OTHER CIRCUMSTANCES the case must be correctly fitted and sealed.

Turn the control thermostat knob fully clockwise and the fan will work.

NOTE: There will be no sparks at the pilot. Take care and light the 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.

MAIN BURNER PRESSURE TEST POINT

MULTIFUNCTIONAL CONTROL

NOTE: Do not adjust any other setting screws

Diagram 6.2

2000225232B

6 Commissioning

The pilot flame length should be as shown in diagram 6.4.

Turn the control thermostat knob to “O” and isolate the boiler from the electrical supply.

Fit the combustion chamber front.

Reconnect the ignition lead to the PCB.

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

Loosen the main burner pressure test point screw and connect a suitable pressure gauge, see diagram 6.2.

Make sure that any remote controls are calling for heat.

Switch on/connect the electrical supply to the boiler and heating system, neon 1 will light.

6.4 Testing - Electrical

Turn the boiler thermostat knob fully clockwise to the maximum setting, which is about 82oC (180oF), neon 2 will light.

The lighting sequence is automatic as follows:-

The fan operates The spark ignition operates The pilot solenoid opens The pilot burner lights

neon 3 will light

4138

SECURING SCREW (4)

VIEWING WINDOW

Diagram 6.3

4146

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 6.3.

Very cold weather may delay the operating sequence.

The main burner will stay alight until switched off, either by the control thermostat or a remote system control.

To make sure that the flame supervision device is working correctly the following should be done.

1. With the main burner alight, turn the gas service cock “Off”, see diagram 6.1.

After a short period the main burner and pilot will go out.

2. The correct working of the flame supervision device is shown by neon 4 going out within 10 seconds and the ignition starting up.

Neons 1, 2 and 3 should stay alight.

3. If the above does not happen, refer to fault finding Section

9.1.

4. To carry on turn the gas service cock “On”, see diagram 6.1.

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

If an external control switches the boiler off, the pump will run on for a predetermined time.

neon 4 will light

NOTE:

PILOT SHIELD REMOVED FOR CLARITY

4139

10 to 20mm FLAME LENGTH

SPARK GAP 2 to 4mm

Diagram 6.4

6.5 Testing - Gas

With the boiler on proceed as follows:-

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 screw clockwise, to decrease pressure, see diagram 6.2.

Should any doubt exist about the gas rate, check it using the gas meter test dial and stop watch, at least 10 minutes after the burner has lit, making sure that all other gas burning appliances and pilot lights are off.

Turn the control thermostat knob fully anticlockwise to “Off”. Remove the pressure gauge from the test point and refit screw, making sure a gas tight seal is made.

2000225232B

6 Commissioning

When the control thermostat is turned to the “Off” position, by hand, wait at least 30 seconds before turning “On” again.

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

Refit the electrical controls box, see diagram 5.8.

NOTE: The neon indicator lights on the printed circuit board are an aid to fault finding, for details refer to Section 9.

6.6 Testing - Open Vented System

Allow the system to reach maximum working temperature and examine for water leaks.

There should be no undue noise in the system and no pumping over of water or entry of air at the open vent above the feed and expansion cistern.

All systems -

The boiler should then be turned off and the system drained off as rapidly as possible, whilst still hot.

6.7 Adjustment - Fully Pumped Open Vented and Sealed Water Systems

When commissioning the system the boiler should first be fired with the bypass fully closed on full service, that is, central heating and domestic hot water. Adjust the pump to the system design setting then balance the system. Having achieved a satisfactory condition operate the boiler with the bypass fully closed on minimum load, normally this will be central heating only with one radiator in the main living area operating. Th e 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.

C between the flow

WING NUT

TOP SEAL

SIDE SEAL

NOTE: MAKE SURE OF CORRECT ENGAGEMENT

WASHER

4081

NUT

Diagram 6.5

4140

6.8 Sealed Water Systems ONLY

Adjust the system to initial design pressure.

The set pointer on the pressure gauge should be set to coincide with the indicating pointer.

6.9 Thermostatic Radiator Valves

If thermostatic radiator valves are fitted care must be taken to ensure that an adequate flow rate through the boiler when they close, refer to the current issue of BS7478 for guidance.

6.10 Protection Against Freezing

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

6.11 Operational Checks and Completion

Adjust the boiler thermostat and any system controls to their required settings.

Do not attempt to adjust the thermostat calibration screw.

Operate the boiler again on full service and check that the balancing is satisfactory, making adjustments as necessary.

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

CONTROLS

COVER

SLIDERS

Diagram 6.6

Fit the front cover by hooking it under at the top and securing with the wing nut, washer and nut previously removed, see diagram 6.5

Fit the controls cover by hooking into the sliders and pushing it back as far as it will go, see diagram 6.6.

2000225232B

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.

8 Servicing

REMEMBER: When replacing a part on this appliance, use only

spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm.

NOTES: To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough.

It is 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.

8.1 Access

Refer to diagram 6.6 and slide the controls cover forwards and off.

Remove the outer case, see diagram 6.5.

NOTE: As an aid to Servicing the air pressure switch tube connection can be used to obtain a products of combustion reading.

Remove the RED tube from the connection on the air pressure switch and insert the analyser probe into the tube.

Switch on the electrical supply to operate the fan and turn on the gas supply.

On completion of the test switch off the electrical supply and the gas supply and reconnect the red tube to the air pressure switch.

It is the Law that servicing is carried out by a competent person.

Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system being out of use during frost and freezing conditions.

Reminder - Leave these instructions and the “Benchmark” logbook with the user.

For IE, 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.

Remove the baffles, see diagram 8.2.

Clean the heat exchanger flueways with a suitable stiff brush.

Remove the paper together with any debris.

8.3 Main Burner

Disconnect the pilot pipe union connector.

Remove the pilot burner securing nut and shakeproof washer, together with the pilot shield.

Remove the pilot burner assembly taking care not to damage the electrode and lead assembly, see diagram 8.3.

Remove the wing nut from the burner support bracket, see diagram 8.4.

SECURING SCREW REAR (2) (KEYHOLE SLOTS, SLACKEN SCREW)

FLUEHOOD

GASKET

SECURING SCREW (2)

Diagram 8.1

4083

8.2 Cleaning Heat Exchanger Flueways

Disconnect the air pressure tubes see diagram 5.4.

Remove the blue and red electrical connections from the fan see diagram 5.4.

Remove the fan complete with the fan duct extension, taking care not to damage the gasket, see diagram 5.4 and 5.7.

Remove the flue hood, noting that there are keyhole slots at the rear, see diagram 8.1.

Remove the combustion chamber cover.

Remove the burner as Section 8.3.

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

BAFFLE (6 off)

12314

Diagram 8.2

2000225232B

8 Servicing

Remove the main burner from the main injector at the rear. Raise the burner up and forward, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot burner assembly.

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

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

8.4 Main Injector

With the main burner removed the main injector can be inspected and cleaned as necessary, see diagram 8.5.

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

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

8.5 Pilot Burner/Electrode and Pilot Injector

Clean the pilot burner and electrode.

To remove the electrode release the spring clip, see diagram

8.6.

When removing and replacing the pilot injector from the pilot burner take care not to damage the electrode, see diagram 8.6, clean the injector by blowing through it.

Check that the spark gap is as shown in diagram 6.4.

8.6 Operational Checks

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

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

Light the boiler and carryout the functional checks as described in Section 6.

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

4142

4141

WING NUT

Diagram 8.4

MAIN BURNER INJECTOR

Diagram 8.5

SECURING NUT AND SHAKEPROOF WASHER

ELECTRODE AND LEAD ASSEMBLY

2000225232B

PILOT SHIELD

UNION

PILOT

CONNECTOR

PIPE

Diagram 8.3

4094

PILOT BURNER

PILOT INJECTOR

SPRING CLIP

ELECTRODE

Diagram 8.6

4143

9 Fault Finding

9.1 Electrical

IMPORTANT: On completion of the Service/Fault Finding task

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

Refer to neon indicators “An Aid to Fault Finding” diagram 9.1, Boiler Fault Finding diagram 9.2, Pump Overrun Fault Finding diagram 9.3 the Functional Flow diagram 9.4, Gravity Domestic Hot Water and Fully Pumped Central Heating, diagram 9.5, Fully Pumped Open Vented or Sealed Water System, the Pictorial Wiring diagram 9.6, Gravity Domestic Hot Water and Fully Pumped Central Heating and diagram 9.7 Fully Pumped Open Vented or Sealed Water System.

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).

9.2 Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out.

Operation will normally resume on the restoration of the electrical supply. If the burner does not relight after an electrical supply failure the overheat device may need resetting.

Remove the control cover, see diagram 6.6 and push the reset button on the front of the control box, see diagram 6.1.

If the cutoff operates at any other time press the reset button and the burner should relight.

If the fault persists refer to fault finding chart.

NOTE: the pump may run for several minutes when power is first applied, regardless of a call for heat.

4120

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

Fault with mains supply or PCB fuse

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 fault finding chart.

NEON INDICATORS

Diagram 9.1

2000225232B

9 Fault Finding

Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of

air. Check the overheat cutoff has not operated, for fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections

and the printed circuit board fuse. Check the air tubes to the air pressure switch. Switch on the electrical supply and check for correct polarity. Turn the

boiler thermostat to its maximum setting. Also check fuses.

Is neon 1 lit?

YES

Is neon 2 lit?

YES

Is neon 3 lit?

YES

Is there 230V~ between SL and N and between L and N ?

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

YES

Is there 230V~ between 3 on thermostat and N ?

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

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

Does fan run?

Does fan Hunt?

YES

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

YES

Replace fan.

YES

Correct power supply problem.

For gravity domestic hot water systems only, check continuity of yellow link. For fully pumped systems, 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.

Is Neon 4 lit?

YES

Does main burner light?

YES

System satisfactory

YES

Is there 230V~ between pilot multi-functional control solenoid blue and brown connections?

YES

Is there a spark at pilot burner?

YES

Does pilot light?

YES

With pilot lit does spark stop?

Is there 230V~ between main multi-functional control solenoid black and blue cables?

YES

Replace multi-functional control.

Isolate supply, test harness continuity. If satisfactory replace printed circiut board.

Check lead continuity and inspect electrode and lead for damage.

Check for pilot jet blockage, incorrect electrode adjustment. If satisfactory replace multi-functional control.

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

Isolate supply, test harness and replace as required.

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

Diagram 9.2

2000225232B

9 Fault Finding

Pump Overrun Operation For Fully Pumped System Only

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

The pump should run for several minutes after remote controls have stopped calling for heat.

The PCB has a timed pump overrun facility.

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.

FOR FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS ONLY Diagram 9.3

2000225232B

9 Fault Finding

bk BLACK br BROWN bl BLUE p PURPLE

SPARK ELECTRODE

FUSE TYPE F1 &F2 (F1A)

KEY

or ORANGE w WHITE r RED y YELLOW

Red Link must be fitted between

SL and 9.

O/H CUTOFF

rbl

CONTROL STAT

FAN

RED LINK

YELLOW

LINK

5742

FUSE TYPE F1 & F2 (F1A)

bk BLACK br BROWN b BLUE p PURLPLE

SPARK ELECTRODE

KEY

or ORANGE w WHITE r RED y YELLOW

brbr

br b

PUMP

O/H CUTOFF

CONTROL STAT

FAN

RED

LINK

5741

AIR PRESSURE SWITCH

br bl

PILOT SOLENOID

MAIN SOLENOID

Yellow Link fitted to bridge out

the overheat cutoff

PUMP WIRED INTO CENTRAL HEATING SYSTEM REMOTE CONTROLS

AIR PRESSURE SWITCH CONNECTIONS

MAIN TERMINAL STRIP CONNECTIONS

CONTROL THERMOSTAT CONNECTIONS

PRINTED CIRCUIT BOARD CONNECTIONS

GRAVITY DOMESTIC HOT WATER AND FULLY PUMPED CENTRAL HEATING

(N/O) (C)

(N/C)

Diagram 9.4 Diagram 9.5

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)

AIR PRESSURE SWITCH CONNECTIONS

MAIN TERMINAL STRIP CONNECTIONS

CONTROL THERMOSTAT CONNECTIONS

PRINTED CIRCUIT BOARD CONNECTIONS

FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEM

AIR PRESSURE SWITCH

br b

PILOT SOLENOID

(N/O) (C)

MAIN SOLENOID

(N/C)

2000225232B

9 Fault Finding

KEY:

b-BLUE bk - BLACK br - BROWN g/y - GREEN/YELLOW or - ORANGE p-PURPLE r-RED y-YELLOW w-WHITE

NC NO

AIR PRESSURE SWITCH

5859

g/y

FAN

GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING

MULTI-FUNCTIONAL CONTROL

ELECTRODE

3-PLUGS

CHASSIS EARTH

g/y

CHASSIS EARTH

g/y

Yellow link fitted to bridge out the overheat cutoff

Pump must be wired into central heating system remote controls and not to control box

Ensure RED LINK connected

between 9 and SL.

g/y

L N

230~50Hz MAINS SUPPLY FUSED AT 3-AMP

SEQUENCE

BOARD

FUSES F1 & F2 (F1A)

g/y

CONTROL THERMOSTAT

OVERHEAT CUTOFF

Diagram 9.6

2000225232B

9 Fault Finding

KEY:

b-BLUE bk - BLACK br - BROWN g/y - GREEN/YELLOW or - ORANGE p-PURPLE r-RED y-YELLOW w-WHITE

AIR PRESSURE SWITCH

g/y

FAN

FULLY PUMPED OPEN VENTED OR SEALED

5860

WATER SYSTEM

MULTI-FUNCTIONAL CONTROL

ELECTRODE

✽ 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).

3-PLUGS

CHASSIS EARTH

g/y

CHASSIS EARTH

g/y

SEQUENCE BOARD

FUSES F1 & F2 (F1A)

g/y

K2 K1

g/y

E L N

✽ See

NOTE:

L N

CIRCULATON PUMP

230~50Hz PERMANENT MAINS SUPPLY FUSED AT 3-AMP

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

CONTROL THERMOSTAT

2000225232B

OVERHEAT CUTOFF

Diagram 9.7

10 Replacement of Parts

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

Before replacing any parts isolate the boiler from the electrical supply and turn the gas supply off at the gas service cock, indicator slot to be vertical.

Unless stated otherwise, all parts are replaced in the reverse order to removal.

After replacing any parts always test for gas soundness and if necessary carryout functional check of controls.

10.1 Access

Gain Access as Section 8.1.

10.2 Control Thermostat - diagram 10.1 and

10.2

Remove and support the electrical control box, refer to Section

5.6.

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

Release the thermostat body by unscrewing the two screws and shakeproof washers in the front of the control box.

Remove the split pin and withdraw the thermostat phial from its pocket. Release the capillary from the base and plastic retaining clip then remove it from the split grommet.

Release the capillary from its clips.

Remove the thermostat complete from the boiler.

Re-assembly NOTE: When fitting the thermostat, make sure that the thermostat phial is covered with heat sink compound and then fully inserted into the phial pocket and that the capillary is within the gland seal, see diagram 10.2. Remake the electrical connections.

There must be no kinks or sharp bends in the capillary.

10.3 Over Heat Cutoff Device - diagram 10.1,

10.2 and 10.2A.

Release the control box as Section 5.6.

Remove the overheat cutoff electrical connections.

Disconnect the air pressure switch plug from the PCB.

Remove the locking nut from the overheat cutoff.

Release the capillary from the retaining clips then remove it from the split grommet.

Slacken the bracket and remove the phial from the pipe.

When refitting use the heat sink compound provided and make sure that the phial is correctly fitted into the groove on the pipe.

CONTROL THERMOSTAT

SHAKEPROOF WASHERS AND SCREWS

CONTROL KNOB

LOCKNUT

ELECTRICAL CONNECTIONS

5754

ELECTRICAL CONNECTIONS YELLOW 2 & 3

SPLIT GROMMET

RETAINING CLIP

Diagram 10.1

2000225232B

10 Replacement of Parts

4103

SPLIT PIN

PHIAL RETAINING BRACKET SECURING SCREW

OVERHEAT CUTOFF DEVICE PHIAL

CONTROL THERMOSTAT PHIAL

RETAINING CLIP

ELECTRICAL PLUGS

CHASSIS EARTH CONNECTION

EARTH CONNECTION

4090

SECURING SCREW (2)

MAIN TERMINAL STRIP

PLASTIC RETAINING CLIP

BOILER THERMOSTAT ELECTRICAL CONNECTION NO.3 "YELLOW" CABLE

SUPPORT POST (4)

IGNITION LEAD

5756

NOTE: All capillaries and cable should be situated within the 'Gland seal'.

GLAND SEAL (Right hand illustrated)

Diagram 10.2

10.4 Control Board (PCB) diagram 10.2A

Release the control box, refer to Section 5.6.

Disconnect the three electrical plugs and ignition lead.

Release the cables from the plastic retaining clip, then disconnect the cables from the PCB to the main terminal strip, control thermostat and earth connection.

Release the main terminal strip and plastic label.

Carefully pull the board away from its supports.

When refitting refer to wiring diagram 9.6 or 9.7 as appropriate.

10.5 Pilot Burner and Pilot Injector

Proceed as Section 8.3 and 8.5.

ELECTRICAL PLUGS

ELECTRICAL CONNECTION BROWN CABLE "SL"

ELECTRICAL CONNECTION BLUE CABLE "N"

Diagram 10.2A

10.6 Electrode

Proceed as Section 8.3 and 8.5.

Gain access as Section 5.6 to remove lead from control box.

10.7 Multifunctional Control - diagram 10.3

Disconnect the pilot supply by unscrewing the tubing nut at the multifunctional control, take care as there is a restrictor on the pilot pipe.

Disconnect the electrical plug.

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

Remove and discard the original “O” rings from the flanged connections and fit the new “O” ring supplied, into recess, before fitting the replacement multifunctional control.

After assembly test for gas soundness and purge in accordance with the current issue of BS6891 or in IE, the current edition of I.S.813 "Domestic Gas Installations".

2000225232B

10 Replacement of Parts

10.8 Solenoid - diagram 10.3

Remove the electrical plug from the multifunctional control. Remove the securing screw and then the solenoid Assembly.

10.9 Main Burner

Remove the main burner as Section 8.3.

4360

RESTRICTOR

10.10 Main Injector

Remove the main burner as Section 8.3.

Remove the main injector as Section 8.4.

PILOT PIPE TUBING NUT

SOLENOIDS

EXTENDED SECURING SCREWS (8)

SECURING SCREW

ELECTRICAL PLUG

Diagram 10.3

2000225232B

10 Replacement of Parts

10.11 Insulation - diagram 10.5

Combustion Chamber Front

Remove the retaining screw then the insulation.

Sides

Slide the insulation out.

Rear

With the side insulation removed the rear insulation can be removed and replaced.

10.12 Viewing Window - diagram 10.6

Remove the old self adhesive aluminium foil gasket and the old mica window. Replace with a new mica window. Peel off the backing paper and secure with new self adhesive aluminium foil gasket, see diagram 10.6. Ensure no air bubbles are trapped underneath the foil.

IMPORTANT

Make sure that the mica window fully covers the opening and that the hole in the aluminium foil gasket is centred over opening.

FRONT INSULATION

4100

RETAINING SCREW

SIDE INSULATION

2000225232B

REAR INSULATION

Diagram 10.5

10 Replacement of Parts

10.13 Air Pressure Switch - diagram 10.7

Release the control box as Section 5.6.

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

When fitting the replacement make sure that the plastic tubes are fitted as shown in diagram 10.7 and that electrical connections are made as shown in diagrams 9.6 or 9.7.

MICA WINDOW

7907

10.14 Fan - diagram 5.4

Remove the electrical connections and disconnect the air tubes.

Remove the fan assembly securing screws at the front and slacken those at the rear and withdraw the assembly.

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

The polarity of the other connections is not important.

SELF ADHESIVE ALUMINIUM FOIL GASKET

AIR PRESSURE SWITCH TUBES

SECURING SCREWS

OPENING (INSIDE FACE OF THE BOILER FRONT COVER)

PEEL OFF BACKING PAPER

Diagram 10.6

CLEAR

4122

RED

ELECTRICAL CONNECTIONS

AIR

PRESSURE

SWITCH

CONTROL BOX

Diagram 10.7

2000225232B

11 Spare Parts

11.1 Part Identification

The key number on the diagram and the list will help to identify the part.

Key No Part No Description GC Part No

1 203374 Multifunctional control *** ***

2 208040 “O” ring 334 592

3 203096 Injector - 50FF 313 305

4 203431 Pilot burner 379 204

5 2000801236 Mica window and gasket

6 2000800432 Fan assembly - 50FF 278 000

7 202626 Spark electrode and lead 313 998

8 K3580 Clip 390 983

9 800849 Thermostat - control - 50FF ******

10 202201 Air pressure switch 313992

11 2000800400 Control knob 313917

13 202015 Fuse 334750

14 900847 Control board (PCB) ******

15 800272 Thermostat cut-off 313 606

11.2 Ordering

When ordering any spare parts please quote the number and description from the list together with the model name and serial number.

If ordering from British Gas also quote the GC number of the appliance and part.

2000225232B

11 Spare Parts

5861

Diagram 11.1

2000225232B

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

2000225232B

Glow-worm Ultimate 50FF User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual