Table of Contents
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Installation and Servicing
Micron
100FF
G.C. No. 41-047-52
Fanned Flue Boiler
This is a Cat I
Reference in these instructions to British Standards and Statutory
Regulations/Requirements apply only to the United Kingdom.
For Ireland the current edition of I.S.813
"Domestic Gas Installations" must be used.
The instructions consist of three parts, User, Installation and Servicing Instructions.
The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety
(Installation and Use) Regulations, be handed to the user on completion of the installation.
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 Glow-worm's own service
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
Instructions for Use
To b e l e f t w i t h t h e u s e r
120FF
G.C. No. 41-047-23
BS 6332
BS 5258
Appliance
2H
Guarantee Registration
to offer our customers' a Comprehensive First Year Guarantee.
organisation on 01773 828100.
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0800 073 2142
Tel: (01773) 828100
Fax: (01773) 828070
Glow-worm,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
www.glow-worm.co.uk
221954D.09.04
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Table of Contents
Related Manuals for Glow-worm Micron 120FF
Summary of Contents for Glow-worm Micron 120FF
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Page 1: Instructions For Use
Comprehensive First Year Guarantee. We recommend you complete and return your Guarantee Registration Card as soon as possible. If this card is missing you can obtain a copy or record your registration by telephoning Glow-worm's own service organisation on 01773 828100. -
Page 2: Table Of Contents
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. - Page 3 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.
- Page 4 Instructions for Use To Light the Boiler WARNING: Sealed Systems 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.
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Page 5: General Data
It is, therefore, important that no alteration is made to the boiler unless approved, in writing, by Glow-worm. Sheet Metal Parts Any alteration not approved by Glow-worm, could invalidate the WARNING: When installing or servicing this boiler care should certification, boiler warranty and could also infringe the statutory be taken when handling sheet metal parts, to avoid any possibility requirements. - Page 6 1 General WATER CONNECTIONS 28mm COPPER PIPE GAS CONNECTIONS RC 1 / 2 ( 1 / 4 in. BSPT) FRONT ELEVATION SIDE ELEVATION MODEL 100FF,120FF 168 132.5 835 78.5 All dimensions are given in millimetres Diagram 1.1 1.7 Contents of Packaging 1.11 Location The boiler is delivered in one pack.
- Page 7 BS6798 document IGE/UP/7/1998. If in doubt seek advice from the local gives detailed guidance on these requirements. gas undertaking or Glow-worm. A compartment used to enclose the boiler must be designed 1.16 Heating System Controls and constructed specifically for this purpose.
- Page 8 1 General *NOTE: Lift weight is with Flue Elbow, Controls Cover and Front Cover removed. TABLE 2. COMPARTMENT AIR VENTS DATA TABLE 1. HIGH LEVEL LOW LEVEL VENTILATION VENT AREA VENT AREA REQUIREMENTS MODEL 100FF 120FF MODEL TOTAL DRY WEIGHT 71.0 kg 71.0 kg VENTILATION...
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Page 9: Flue Terminal
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 obstructions, other terminals and ventilation openings are shown in diagram 2.1. For Ireland the minimum distances for flue terminal positioning must be those detailed in I.S.813 "Domestic Gas Installations". -
Page 10: Water Systems
3 Water Systems 3.1 Frost Protection OPEN VENTED FULLY PUMPED WATER SYSTEM If the position of the boiler is such that it may be vulnerable to RECOMMENDED RELATIONSHIP BETWEEN freezing it should be protected as specified in the current issue PUMP COLD FEED AND VENT of BS5422. - Page 11 Local Water Company Byelaws, see also the current issue of If an inhibitor is to be used, contact a manufacturer or BS6700. Glow-worm, for their recommendations as to the best product If fitting into an existing system, the local authority must also be to use.
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Page 12: Flue And Appliance Preparation
A Flue Bend Kit up to 2 metres and a Vertical Flue Kit up to 2 remove template as diagram 4.3. metres plus vertical terminal can be supplied, see Glow-worm “Flue Options Guide” for configurations available. 4.5 Flue Hole Cutting Flue Bend Pack - Pt.No. - Page 13 4 Flue and Appliance Preparation TOP BOILER FLUE/BOILER MOUNTING 65.5 CENTRELINE HOLES TEMPLATE BOILER FLUE/BOILER MOUNTING 172.5 CENTRELINE BRACKET 172.5 MOUNTING BRACKET FIXING POINTS 3/16in. dia. PLUG 7dia. NO. 12x2in. Diagram 4.4 4.6 Wall Mounting Bracket TELESCOPIC FLUE Reposition the template, making sure of dimensional alignment 598mm with the flue hole.
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Page 14: Boiler Installation
4 Flue and Appliance Preparation 4.9 Side Flue NOTE: The telescopic flue assembly will require drilling. Mark the air duct/terminal assembly and the flue duct at the Locate the flue duct/elbow into the air duct/terminal spigot and lengths shown in diagram 4.5 then cut to length, cutting square the air duct/terminal into the flue elbow making sure the correct and removing any burrs. - Page 15 5 Boiler Installation ELECTRICAL CONNECTIONS CONTROLS COVER FRONT COVER CLEAR FAN SECURING WING SCREWS FLUE HOOD SECURING SCREW (4) AIR PRESSURE SHAKEPROOF CLEAR SENSING PIPES WASHER ASSEMBLY Diagram 5.1 SWING BRACKET Diagram 5.3 SECURING BRACKET Pipe FLUE omitted HOOD SECURING for clarity SCREWS (2) FLUE HOOD...
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Page 16: Flue Fixing
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. 152 DIA Place the flue assembly into the hole. Check that the flue CORE terminal is correctly positioned and is the distance required from DRILLED... -
Page 17: Electrical Connectors
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. SECURING SCREWS (2) 7.2 Electrical Connection WARNING: This boiler must be earthed. -
Page 18: Commissioning
8 Commissioning IMPORTANT NOTE: The warning notice attached to RESET the front of the boiler casing must only be removed BUTTON by the user. 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. - Page 19 The ignition spark stops Neon 4 will light The main solenoid opens MICRON 100FF 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.
- Page 20 8 Commissioning 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 PRESSURE and pilot lights are off. ADJUSTMENT SCREW The gas rates shown in Table 3 are for guidance only, dependent...
- Page 21 8 Commissioning 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 RETAINING close, refer to the current issue of BS7478 for guidance. CLIP 8.10 Operational Checks and Completion Adjust the boiler temperature control and any system controls to their required settings.
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Page 22: Instructions To The User
Do not use reconditioned or copy parts that have not been clearly authorised Remove the cleaning plate from the combustion chamber by Glow-worm. cover, see diagram 8.2. NOTES: To ensure the continued efficient and safe operation... - Page 23 10 Servicing 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”...
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Page 24: Fault Finding
10 Servicing MAIN BURNER INJECTOR Diagram 10.6 MICRON 100FF 50mm PILOT SPRING BURNER CLIP PILOT ELECTRODE INJECTOR ELECTRODE PILOT 20mm BURNER 40mm SECURING SEMI STIFF SCREW NYLON BRISTLES PILOT CLEANING BRUSH INJECTOR CLEANING PLATE Diagram 10.5 MICRON 120FF Diagram 10.7... - Page 25 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.
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Page 26: Electrical Supply Failure
11 Fault Finding 11.2 Electrical Supply Failure Failure of the electrical supply will cause the burner to go out. bk BLACK or ORANGE Operation will normally resume on the restoration of the electrical br BROWN w WHITE supply. If the burner does not relight after and electrical failure BLUE the overheat device may need resetting. - Page 27 11 Fault Finding WATER PRESSURE - YELLOW - BLUE SWITCH - WHITE - BLACK - PURPLE - BROWN - GREY g/y - GREEN/ YELLOW - RED MULTI-FUNCTIONAL CONTROL ELECTRODE PLUG PRESSURE SEQUENCE SWITCH BOARD CHASSIS EARTH CHASSIS EARTH NOTE:- Bridge out Water Pressure Switch between K1 &...
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Page 28: Replacement Of Parts
12 Replacement of Parts NOTE: Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT Before replacing any parts isolate the boiler from the electrical supply and turn the gas supply off at the gas service cock, SHAKEPROOF indicator slot to be vertical. - Page 29 12 Replacement of Parts Remove and discard the original “O” rings from the flanged 12.11 Insulation - diagram 12.4 connection and fit the new “O” rings supplied, into recess, before fitting the replacement multifunctional control. Combustion Chamber Front After assembly test for gas soundness and purge in accordance Remove the retaining screw then the insulation.
- Page 30 12 Replacement of Parts 12.13 Air Pressure Switch - diagram 12.6 Release the control box as Section 7.1 EXTENDED Remove the pressure tubes and the electrical connections from SCREW the PCB, release the screws and remove the switch. (8 off) RESTRICTOR When fitting the replacement make sure that the plastic tubes (120FF Only)
- Page 31 12 Replacement of Parts 12.14 Fan - diagram 5.3 Remove the electrical connections and disconnect the air pressure tubes. WATER PRESSURE Remove the fan assembly securing screws. SWITCH Make sure that the earth connection is remade onto the new fan assembly.
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Page 32: Spare Parts
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. 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.
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