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Glow-worm Micron 80FF User Manual

Glow-worm Micron 80FF
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2000225230B.09.04
All replacement parts
All labour charges
All call-out charges
Thank you for installing a new Glow-worm appliance in your home.
Glow-worm appliances' are manufactured to the very highest standard so we are pleased
to offer our customers' a Comprehensive First Year Guarantee.
We recommend you complete and return your Guarantee Registration Card as soon as possible.
If this card is missing you can obtain a copy or record your registration by telephoning Glow-worm's own service
organisation on 01773 828100.
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
Guarantee Registration
Fanned Flue Boiler
This is a Cat I
2H
Appliance
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.
To be left with the user
7319
Instructions for Use
Installation and Servicing
G.C. No. 41-047-51
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0800 073 2142
80FF
Micron
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
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Glow-worm Micron 80FF Specifications

General IconGeneral
MountingWall Mounted
Output24 kW
Fuel TypeNatural Gas
Weight31 kg
Flow Rate (l/min)9.8 l/min
Central Heating Flow Temperature Range30 - 80°C
Hot Water Flow Rate at 35°C Rise9.8 l/min

Summary

Guarantee Registration

Register Your Appliance

Information on registering your Glow-worm appliance for its first year guarantee protection.

Important Information

Testing and Certification

Details on boiler testing, certification, and compliance with safety and performance standards.

CE Mark

Explanation of the CE mark and its compliance with EU directives on efficiency and safety.

Information for Installer and Service Engineer

Information regarding substances hazardous to health, specifically insulation pads and glass yarn.

Spare Parts

Guidance on using only approved spare parts to maintain safety and performance.

Instructions for Use

Introduction

Read these instructions for safe and economical boiler use. Boiler is fully automatic with one user control.

Gas Leak or Fault

Immediate actions to take in case of a gas leak or fault, including shutting off gas and ventilating.

Electrical Supply Failure

Procedure to follow if the electrical supply fails, including boiler restart and safety cutoff reset.

Safety Temperature Limiter

Actions to take if the safety temperature limiter operates, including checking for overheating.

Protection Against Freezing

Measures to prevent freezing during periods of disuse, including system draining and frost protection features.

Maintenance

Recommendation for regular checks and servicing to ensure continued efficient and safe operation.

Cleaning

Instructions for cleaning the boiler casing safely, avoiding abrasive cleaners.

To Turn the Boiler On

Step-by-step guide on how to turn the boiler on, including pressure checks and control knob operation.

To Turn the Boiler Off

Guidance on turning the boiler off for short or long periods.

Optional Programmer

Information on using an optional programmer for automatic on/off switching of the heating system.

Installation - 1 General

Important Notice

Boiler is for Natural Gas (G20) only, must be installed by a competent person, and can be used on vented or sealed systems.

Sealed Components

User must not interfere with or adjust sealed parts.

Sheet Metal Parts

Warning about handling sheet metal parts to avoid personal injury.

Statutory Requirements

Details of UK and IE regulations and codes of practice for boiler installation.

Data

Information on SEDBUK rating, SAP use, and test data certification by B.S.I.

Range Rating

Boiler can be range rated to suit system requirements; refer to data label for settings.

1 General

Gas Supply

Requirements for gas installation in GB and IE, including pressure and soundness testing.

Electrical Supply

Guidelines for electrical supply connection, earthing, polarity, and cable types.

Contents of Packaging

Information on the boiler packaging contents, which may vary depending on flue system.

Water System

Notes that the boiler may be fitted to an open vented or sealed water system.

Draining Tap

Details on system and boiler draining points and precautions during draining.

Safety Valve

Note on safety valve requirements for open vented systems.

1 General

Location

Guidance on suitable installation locations, including bathroom zones and electrical safety considerations.

Boiler Clearances

Minimum operational and servicing clearances required around the boiler for safe installation and maintenance.

Room Ventilation

Information that the boiler is room sealed and does not require additional room air vents.

Boilers in a Compartment

Requirements for installing boilers in cupboards or compartments, including minimum clearances.

Timber Frame Building

Guidance for installing boilers in timber frame buildings, referencing IGE/UP/7/1998.

Anti-theft Kits

Information about the availability of anti-theft kits for the appliance.

2 Flue and Ventilation

Terminal Position

Minimum siting dimensions for the terminal from obstructions, referencing UK and IE regulations.

Flue Options

Details of available flue systems, extension kits, and bend kits for installation.

2 Flue and Ventilation

Terminal Guard

Requirements for installing a terminal guard if persons could come into contact with the terminal.

3 Water Systems

Frost Protection

Built-in frost stat functionality and system vulnerability considerations.

Pump

Guidance on pump fitting, setting temperature difference, and microbore systems.

Bypass

Information on when a bypass is required and its connection, especially with TRVs.

Water System

Requirements for open vented systems, including supply and cistern fitting.

Domestic Hot Water System

General requirements for domestic hot water circuits and fittings, referencing standards.

Cylinder

Recommendations for indirect hot water cylinders and temperature control.

3 Water Systems

Open Vented Fully Pumped Heating and Domestic Hot Water

Connection requirements for open vented systems as shown in diagrams.

Inhibitor

Attention to BS5449 and BS7593 on inhibitor use and system cleaning.

Sealed Water Systems

Installation compliance with relevant British Standards for sealed water systems.

Safety Valve

Requirements for safety valve fitting in sealed systems, including pressure and connections.

Expansion Vessel - Sealed Systems only

Guidance on diaphragm expansion vessel selection and sizing for sealed systems.

Pressure Gauge - Sealed Systems only

Requirement for a permanently fitted pressure gauge in sealed systems.

Domestic Hot Water Cylinder

Suitability of indirect coil cylinders and pressure requirements for domestic hot water.

Domestic Hot Water System - Unvented

Compliance with regulations for unvented storage systems and local authority advice.

Filling a Sealed Water System

Provision for system filling at low level and compliance with BS5449.

Water Makeup

Provision for replacing water lost from the system using a make-up vessel.

4 Flue and Appliance Preparation

Top Outlet Flue Pack

Details on flue length calculations and clearances for top outlet flue packs.

Rear Outlet Flue Pack

Description of rear outlet flue packs and their assembly with extension kits.

Easyfit/Std./Extd. Top Outlet Flue Pack & 1 Metre Extension Kit

Guidance on joining extension kits and maximum flue system lengths.

Flue Packs - Maximum Distances

Table showing maximum distances for flue packs from boiler mounting face and casing.

4 Flue and Appliance Preparation

Flue Position and Length

Determining flue application, length, and terminal position, including instructions for kits.

Flue Preparation

Information on internal and external flue installation, including wall liner kit use.

Rear and Side Flue Application

Selecting boiler location and flue application, with template use for marking.

Flue Hole Cutting

Instructions for cutting the flue hole, including drill size and optional wall liner kit.

Wall Mounting Bracket

Steps for positioning the template, marking fixing points, and securing the mounting bracket.

Flue Duct

Extending telescopic flue, ensuring overlap, and terminal projection beyond wall face.

4 Flue and Appliance Preparation

Internal Access Flue

Instructions for flue system installation from inside using an optional wall liner kit.

Rear Flue Fixing

Steps for fitting flue duct extension, fan elbow, and securing the assembly for rear flue.

Top, Side Flue Fixing

Procedure for fitting flue duct extension and fan elbow for top or side flue arrangements.

Flue Positioning

Guidance on pushing the flue assembly into the hole and securing it to the boiler.

5 Boiler Installation

Unpacking

Instructions for unpacking the boiler and checking items against the pack contents list.

Boiler Preparation

Steps to prepare the boiler, including removing casing, opening controls cover, and fitting tail pipes.

Mounting the Boiler

Procedure for fitting blanking plates, flue spigots, and securely mounting the boiler to the wall.

5 Boiler Installation

Rear Flue Fixing

Detailed steps for fitting the fan elbow, retaining clamp, and securing the flue duct for rear flue connections.

Top Flue Fixing

Instructions for fitting 'O' rings, air deflector, flue duct extension, and fan elbow for top flue.

Water Circulation System

Steps for completing water connections, filling, venting, flushing, and checking for leaks.

Gas Connection

Requirements for gas connection, including testing for soundness and purging.

5 Boiler Installation

Control Box Access

Procedure for accessing the control box by loosening the securing screw and swinging it open.

Electrical Connection

Detailed instructions for making electrical connections, including earthing and cable types.

Pump Connection

Routing the pump cable and connecting it to the control box terminal block.

Testing

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

6 Commissioning

All Systems

Commissioning procedures for all systems, including water flushing, pump refitting, and air venting.

Sealed Water Systems Only

Specific commissioning steps for sealed systems, including pressure checks and safety valve testing.

Initial Lighting and Testing

Procedure for initial boiler lighting, testing controls, gas soundness, and electrical safety.

6 Commissioning

Testing - Electrical

Detailed electrical testing procedures, including lighting sequence and safety checks.

Testing - Gas

Gas soundness testing, main burner gas pressure checks, and gas rate measurement.

Testing - All Water Systems

Checking for water leaks at maximum temperature and system draining/refilling.

Adjustment - Fully Pumped Open Vented and Sealed Water Systems

Adjusting pump settings and balancing the system for optimal performance.

Thermostatic Radiator Valves

Considerations for systems with TRVs, including bypass requirements and temperature differences.

Completion

Final steps including setting controls, completing logbook, and flue gas testing.

7 Instructions to the User

Safe and Efficient Operation

Instructing the user on safe and efficient operation, system checks, and servicing recommendations.

User Responsibilities

Highlighting user duties regarding property letting, sealed components, and competent person servicing.

Frost Protection Advice

Advising the user on precautions to prevent system damage from freezing conditions.

8 Servicing

Products of Combustion Check

Procedure for obtaining products of combustion readings using an analyser.

Access

Steps to gain access to the boiler components for servicing.

Burner

Instructions for removing, cleaning, and refitting the burner and baffle support.

Cleaning Heat Exchanger Flueways

Steps for cleaning the heat exchanger flueways, including removing baffles and debris.

8 Servicing

Injector Manifold

Inspection and cleaning of the injector manifold, including advice on injector removal and refitting.

Operational Checks

Checks to be performed after service before refitting the case, including case seal and flue examination.

9 Fault Finding

Electrical

Importance of repeating electrical checks after service/fault finding, referring to various diagrams.

Electrical Supply Failure

Actions to take for burner failure due to electrical supply issues, including reset procedures.

Pump Overrun Operation

Troubleshooting the timed pump overrun facility and checks required before using fault finding charts.

9 Fault Finding

General Fault Finding Prerequisites

Ensuring gas, electricity, and water availability and checking external controls before starting fault finding.

Ignition and Burner Fault Diagnosis

Step-by-step fault finding process for ignition and burner issues, including LED indications.

9 Fault Finding

LED Fault Coding

Table detailing LED status and corresponding fault conditions for troubleshooting.

10 Replacement of Parts

Important Notes for Parts Replacement

General notes on safety, isolation, gas soundness testing, and functional checks before and after part replacement.

Electrical Thermistor Replacement

Detailed steps for accessing and replacing the electrical thermistor, including disconnection and refitting.

Safety Temperature Limiter Replacement

Procedure for accessing and replacing the safety temperature limiter device.

10 Replacement of Parts

Control Board (PCB) Replacement

Steps for accessing and replacing the control board (PCB), including disconnection and refitting.

Electrode Replacement

Procedure for removing and refitting the electrode, including checking the spark gap.

Multifunctional Control Replacement

Instructions for accessing and replacing the multifunctional control, including gas connection.

Insulation Replacement

Guidance on removing and replacing combustion chamber front, side, and rear insulation.

10 Replacement of Parts

Air Pressure Switch Replacement

Steps for removing and replacing the air pressure switch, including tubes and connections.

Fan Replacement

Procedure for removing and refitting the fan assembly, including electrical connections and air tubes.

11 Spare Parts

Part Identification

Diagram and list to help identify specific spare parts by part number and location.

Ordering Spare Parts

Information required when ordering spare parts, including part number, description, model, serial, and GC number.

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