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Installation and Servicing
70FF 80FF
G.C. No. 41-047-57
Cat I
2H
Fanned Flue Boiler
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:
❏
✔
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
G.C. No.41-047-58
Cat II
2H3P
BS 6332
BS 5258
Guarantee Registration
to offer our customers' a Comprehensive First Year Guarantee.
Service number 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
2000225233A.10.04
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Summary of Contents for Glow-worm Ultimate 70FF
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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 the Glow-worm Customer Service number 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 Instructions for Use To obtain service, please call your installer or Glow-worm’s own Introduction Service Organisation using the telephone number given on the WARNING: It is important that the case (not the controls tray) controls tray. is not disturbed or removed other than for servicing by a Please be advised that the ‘Benchmark’...
- Page 4 Instructions for Use The cable coloured brown must be connected to the terminal Cleaning marked “L” or red. WARNING: This appliance contains metal parts (components) The cable coloured green/yellow must be connected to the and care should be taken when handling and cleaning, with terminal marked “E”, or green or the earth symbol particular regard to edges.
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Page 5: General Data
1 General Data WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) SIDE ELEVATION FRONT ELEVATION MODEL 70FF/80FF Diagram 1.1 The Water Fittings Regulations or Water byelaws in Scotland. IMPORTANT NOTICE The Health and Safety at Work Act, Control of Substances This boiler is for use on Natural Gas (G20) as distributed in the Hazardous to Health (COSHH). - Page 6 Glow-worm. In GB this is BS 6891. Any alteration that is not approved by Glow-worm, could In IE this is the current edition of I.S.813 "Domestic Gas invalidate the B.S.I. Certification of the boiler, warranty and Installations".
- 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 and constructed specifically for this purpose. An existing 1.16 Heating System Controls...
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Page 8: Flue & Ventilation
2 Flue and Ventilation NOTE: Detailed recommendations for flue 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". -
Page 9: Water Systems
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". 80FF 1000 In GB it is necessary to comply with the Water Supply (Water Fittings) Regulations 1999 (for Scotland, the Water Byelaws 70FF 2000, Scotland). -
Page 10: Expansion Vessel
3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 28mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION 22 X 28 CISTERN UNION 1150mm CONNECTION MIN. -
Page 11: Domestic Hot Water Cylinder
3 Water Systems 3 LITRES (0.66 gals) MAKE-UP BOTTLE RELEASE (if required) POINT AUTO VENT NON-RETURN VALVE FILLING POINT IF REQUIRED 22mm (min) BY-PASS WITH LOCKSHIELD VALVE FLOW CIRCULATING SAFETY PUMP VALVE PRESSURE GAUGE RETURN DRAIN COCK (Make-up BOILER alternatives) EXPANSION VESSEL Diagram 3.4... -
Page 12: Flue And Appliance Preparation
4 Flue and Appliance Preparation 4.1 Unpacking 4.3 Flue Preparation Open the carton, check the items supplied against the boiler All flue assemblies are designed for internal installation (optional pack contents list on the flap, see diagram 4.1. wall liner is required), given that there is sufficient clearances opposite to the flue for the installation of the flue. - Page 13 4 Flue and Appliance Preparation 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 115mm need to be made good from the outside.
- Page 14 4 Flue and Appliance Preparation 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. 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...
- Page 15 4 Flue and Appliance Preparation 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.
- Page 16 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 and through the hole such that it is within the wall and does not stick out into the room, see diagram 4.12.
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Page 17: Boiler Installation
5 Boiler Installation 5.1 Boiler Preparation With the boiler still in the bottom tray, slide the controls tray CONTROLS upwards and remove it as shown in diagram 5.1. COVER Remove the front cover by undoing (and keeping) the screw and wing nuts and lifting the front cover off, see diagram 5.1. - Page 18 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.
- Page 19 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 (REAR FLUE OUTLET ILLUSTRATED) FLUE MANIFOLD SPIGOT FAN DUCT EXTENSION...
- Page 20 5 Boiler Installation 5.7 Electrical Connection WARNING: This boiler must be earthed. FIXING SCREWS Take care not to damage any internal wiring and capillaries. Take 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.
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Page 21: Commissioning
6 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. OVERHEAT 6.1 All Systems SAFETY CUT-OFF 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. - Page 22 6 Commissioning 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 SECURING system, neon 1 will light.
- Page 23 6 Commissioning 6.6 Testing - Open Vented SEAL Allow the system to reach maximum working temperature and examine for water leaks. SIDE SEAL 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.
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Page 24: Instructions To The User
Do not use Remove the baffles, see diagram 8.2. reconditioned or copy parts that have not been clearly authorised by Glow-worm. Clean the heat exchanger flueways with a suitable stiff brush. NOTES: To ensure the continued efficient and safe operation Remove the paper together with any debris. - Page 25 8 Servicing Remove the main burner from the main injector at the rear. Raise the burner up and forwards, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot p[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.
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Page 26: Fault Finding
9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure IMPORTANT: On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on restoration of the electrical connections the earth continuity, polarity, short circuit and supply. - Page 27 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.
- Page 28 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
- Page 29 9 Fault Finding bk BLACK or ORANGE br BROWN w WHITE BLUE PURLPLE YELLOW LINK PUMP SPARK ELECTRODE O/H CUTOFF FUSE F1 & F2 (F1A) CONTROL STAT (N/O) PRESSURE SWITCH (N/C) PILOT SOLENOID MAIN SOLENOID Remove red link between 9 and SL when fitting a time control etc (if no switch is fitted, link will make the circulation pump run constantly) AIR PRESSURE SWITCH CONNECTIONS...
- Page 30 9 Fault Finding KEY: FULLY PUMPED OPEN - BLUE VENTED OR SEALED bk - BLACK WATER SYSTEM - BROWN g/y - GREEN/YELLOW - ORANGE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE - PURPLE PRESSURE SWITCH ELECTRODE PLUG CHASSIS CHASSIS EARTH EARTH ✽...
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Page 31: Replacement Of Parts
10 Replacement of Parts NOTE: Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT SHAKEPROOF Before replacing any parts isolate the boiler from the electrical WASHERS AND supply and turn the gas supply off at the gas service cock, SCREWS indicator slot should be vertical. - Page 32 10 Replacement of Parts BOILER PHIAL THERMOSTAT ELECTRICAL PLUGS POCKET ELECTRICAL SPLIT CONNECTION NO.3"YELLOW" THERMOSTAT CABLE PUMP OVERHEAT OVERRUN CUTOFF PHIAL ELECTRICAL CONNECTION OVERHEAT "WHITE" CUTOFF PHIAL CABLE DEVICE POCKET PHIAL CHASSIS EARTH CONNECTION SUPPORT IGNITION POST (4) LEAD SPLIT RETAINING CLIP MAIN...
- Page 33 10 Replacement of Parts 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. RESTRICTOR Disconnect the electrical plug. Support the multifunctional control, remove the four extended screws from the flanged connections at the left and right hand PILOT PIPE side.
- Page 34 10 Replacement of Parts MICA WINDOW RETAINING SCREW OPENING (INSIDE FACE OF THE BOILER FRONT COVER) FRONT INSULATION PEEL OFF SELF ADHESIVE BACKING ALUMINIUM FOIL PAPER GASKET Diagram 10.5 CLEAR AIR PRESSURE SWITCH TUBES SECURING SCREWS SIDE INSULATION REAR INSULATION PRESSURE SWITCH Diagram 10.4...
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Page 35: Spare Parts
10 Spare Parts 11.1 Part Identification The key number on the diagram and the list will help to identify the part. 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. - Page 36 11 Spare Parts Diagram 11.1 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 2000225233B...
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