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Installation and Servicing
100FF
G.C. No. 41 047 59
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 rules in force must be used.
The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration
Card. 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.
Glow-worm appliances' are manufactured to the very highest standard so we are pleased
In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall 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
One Contact Local Service
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. 41 319 75
BS 6332
BS 5258
Appliance
2H
Guarantee Registration
Thank you for installing a new Glow-worm appliance in your home.
to offer our customers' a Comprehensive First Year Guarantee.
return as soon as possible.
Service number 01773 828100.
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
221966B.04.03
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Table of Contents
Related Manuals for Glow-worm Ultimate 100FF
Summary of Contents for Glow-worm Ultimate 100FF
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Page 1: Instructions For Use
Guarantee Registration Thank you for installing a new Glow-worm appliance in your home. Glow-worm appliances' are manufactured to the very highest standard so we are pleased to offer our customers' a Comprehensive First Year Guarantee. In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and return as soon as possible. -
Page 2: Important Information
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 Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4. -
Page 3: Table Of Contents
Important Information CONTENTS DESCRIPTION SECTION PAGE No. Introduction INSTRUCTIONS Lighting the Boiler FOR USE General Data INSTALLATION Flue Terminal INSTRUCTIONS Water Systems Flue and Appliance Preparation Boiler Installation Flue Fixing Electrical Connectors Commissioning Instructions to the User Servicing SERVICING Fault Finding INSTRUCTIONS Replacement of Parts Spare Parts... - Page 4 Instructions for Use Maintenance CONTROLS COVER 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.
- Page 5 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 500mm installation/servicing company.
- Page 6 All dimensions are given in millimetres (except as noted). The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is Ultimate 100FF = 79, Ultimate 120FF = 78.1. The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by B.S.I.
- Page 7 1 General TABLE 2. 100FF DATA TABLE 1. Med. Max. RANGE RATING Min. MODEL 100FF 120FF NOMINAL TOTAL DRY 26.44 29.24 32.38 HEAT WEIGHT 71.0 kg 71.0 kg 90,210 99,760 110,485 INPUT(NETT) Btu/h (Including (157 lb) (157 lb) Terminal) NOMINAL 23.45 26.38 29.31...
- Page 8 1 General 1.8 Water System This boiler may be fitted to an open vented or sealed water system. It is recommended that plastic pipes for primary pipework should not be used for this boiler. PLAN 1.9 Drain VIEW 500mm System A draining tap must be provided at the lowest points of the Additional clearances may be required for installation...
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Page 9: Flue Terminal 2
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. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times. -
Page 10: Water Systems 3
3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. It is recommended that plastic pipes for primary pipework should not be used for this boiler. 700mm (120FF 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to 450mm (100FF freezing it should be protected as specified in the current issue... -
Page 11: Water Systems
3 Water Systems RETURN FLOW OPEN VENTED FULLY PUMPED WATER SYSTEM RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT 28mm 22mm VENT PIPE (MIN.) 450mm MIN. FEED AND HEIGHT EXPANSION CISTERN 15mm (MINIMUM) COLD FEED 1150mm MIN. PUMP 22mm VENT & 15mm COLD FEED TO BE FITTED IN ACCORDANCE WITH BS 5449 There must... -
Page 12: Filling A Sealed Water System
3 Water Systems 3 LITRES (0.66 gals) MAKE-UP BOTTLE RELEASE (if required) POINT AUTO VENT NON-RETURN FILLING POINT VALVE FLOW CIRCULATING PUMP 22mm (min) BY-PASS WITH SAFETY LOCKSHIELD PRESSURE VALVE VALVE GAUGE RETURN DRAIN COCK (Make-up (Make-up alternatives) alternatives) EXPANSION VESSEL BOILER Diagram 3.4... -
Page 13: Flue And Appliance Preparation 4
4 Flue and Appliance Preparation 4.1 Unpacking For a wall thickness up to 300mm, provided that there is sufficient space and the optional wall liner kit is used the flue can Open the carton, check the items supplied against the boiler be fully installed from the inside. -
Page 14: Flue And Appliance Preparation
4 Flue and Appliance Preparation 4.4. Rear and Side Flue Application Take the template from the boiler pack and position it on the wall, making sure that the minimum clearances are maintained, see diagram 1.2. For a rear flue mark the position of the flue as diagram 4.4. 120 mm For a side flue, extend the centre line horizontally left or right to MINIMUM... - Page 15 4 Flue and Appliance Preparation 4.7 Flue Length For a rear flue, measure the distance from the outside wall face to the boiler mounting wall. Check that the flue length will be suitable, see diagram 4.2. For a side flue, measure the distance from the outside wall face to the boiler centre line.
- Page 16 4 Flue and Appliance Preparation FOAM SEAL LONG FLUE TERMINAL STANDARD FLUE TERMINAL 20mm WALL THICKNESS- T MINUS 55mm UP TO 300mm FOAM SEAL BOILER CENTRE LINE Q MINUS 55mm WALL THICKNESS- OVER 300mm Diagram 4.9 Diagram 4.11 FLUE ELBOW SECURING SCREW (2) SEALING TAPE...
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Page 17: Boiler Installation 5
5 Boiler Installation Break the air pressure switch tube connections from the fan, 5.1 Boiler Preparation see diagram 5.3. With the boiler still in the bottom tray, slide the controls cover Remove the fan assembly by removing the screws and sliding upwards and remove it as shown in diagram 5.1. -
Page 18: Boiler Installation
5 Boiler Installation 5.3 Water Circulation System Complete the water connections to the boiler. Fill, vent and flush system. Check for any leaks and put right. 5.4 Safety Valve Discharge Fit a suitable discharge pipe to the safety valve and route it outside the building so that any discharge can be seen but will not cause injury to person, damage to property or any electrical installation. -
Page 19: Flue Fixing 6
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 20: Electrical Connectors 7
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. -
Page 21: Commissioning 8
8 Commissioning Please ensure the "Benchmark" logbook is completed and left with the user. 8.1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place. - Page 22 8.2. The main burner will stay alight until switched off, either by the control thermostat or a remote system control. ULTIMATE 100FF To make sure that the flame supervision device is working correctly the following should be done: Very cold weather may delay the operating sequence.
- Page 23 8 Commissioning 8.8 Sealed Water System ONLY Turn the control thermostat knob fully anticlockwise to “O”. Remove the pressure gauge from the test point and refit screw, Adjust system to initial design pressure. The set pointer on the making sure a gas tight seal is made. pressure gauge should be set to coincide with the indicating When the control thermostat is turned to “Off”...
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Page 24: Instructions To The User 9
8 Commissioning 8.10 Operational Checks and Completion 8.11 Protection against Freezing Adjust the control thermostat and any system controls to their If the boiler is to be out of use for a period of time during severe required settings. weather conditions we recommended that the whole of the system, including the boiler, be drained off to avoid the risk of Do not attempt to adjust the thermostat calibration screw. - Page 25 10 Servicing 10.2 Cleaning Heat Exchanger and Burner Disconnect the air pressure tubes, see diagram 5.3. Remove the blue and red electrical connections from the fan, see diagram 5.3. Remove the fan taking care not to damage the gasket, see diagram 5.3.
- Page 26 Check that the spark gap is as shown in diagram 8.3. 50mm PILOT SPRING BURNER CLIP 20mm ELECTRODE 40mm PILOT SEMI STIFF INJECTOR NYLON BRISTLES CLEANING BRUSH CLEANING PLATE Diagram 10.5 ULTIMATE 100FF MAIN BURNER PILOT INJECTOR BURNER ELECTRODE PILOT INJECTOR SECURING SCREW Diagram 10.6 Diagram 10.7 ULTIMATE 120FF 221966B...
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Page 27: Fault Finding
11 Fault Finding 11.1 Electrical 11.2 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 the restoration of the electrical connections, the earth continuity, polarity and short circuit and supply. - Page 28 11 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated. For fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
- Page 29 11 Fault Finding bk BLACK or ORANGE br BROWN w WHITE BLUE PURPLE YELLOW GREY SPARK ELECTRODE LINK PUMP FUSE TYPE F1 & F2 LINK (F1A) WATER PRESSURE SWITCH Pump overrun Operation for Fully CONTROL Pumped System Only STAT The PCB has a pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat.
- Page 30 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 31: 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 32 12 Replacement of Parts 12.4 Control Board (PCB) - diagram 12.2A 12.7 Multifunctional Control - diagram 10.3 Release the control box, refer to Section 7.1. Disconnect the pilot supply by unscrewing the tubing nut at the multifunctional control. Disconnect the three electrical plugs and ignition lead. 120FF ONLY.
- Page 33 12 Replacement of Parts 12.9 Main Burner SECURING SCREW Remove the main burner as Section 10.2. 12.10 Main Injector Remove the main burner as Section 10.2. Remove the main injector as Section 10.3. 12.11 Insulation - diagram 12.4 FRONT INSULATION Combustion Chamber Front Remove the retaining screw then the insulation.
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Page 34: Spare Parts
12 Replacement of Parts 12.15 Water Pressure Switch - Sealed Water 12.14 Fan - diagram 5.3 System Only Remove the electrical connections and disconnect the air pressure tubes. Release the water pressure and drain, refer to Section 3. Remove the fan assembly securing screws. Disconnect the electrical connections at the microswitch, see diagram 12.7. - Page 35 13 Spare Parts Key No Part No Description GC Part No 800442 Multifunctional control 278 021 208040 “O” ring 334 592 205727 Injector - 100FF 278 197 205726 Injector - 120FF 278 196 203432 Pilot burner - 100FF 278 023 203434 Pilot burner - 120FF E00 998...
- Page 36 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221966B...
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