background image

3

221785B

Instructions for Use

Introduction

Please read these instructions and follow them carefully for the
safe and economical use of your boiler.

The Ultimate series are central heating boilers designed to
provide heating and indirect domestic hot water.

Important Notice

This boiler is for use only on natural gas G20.

The Gas Safety (Installation and Use)
Regulations

In your interests and that of gas safety it is the Law that ALL gas
appliances are installed by competent person in accordance
with the current issue of the above regulations.

Gas Leak or Fault

If a gas leak or fault exists or is suspected, the BOILER MUST
BE TURNED Off, including the electrical supply and MUST
NOT BE USED UNTIL THE FAULT HAS BEEN PUT RIGHT.
Advice/help should be obtained from your installation/servicing
company or the local gas undertaking.

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 there is a duty
of 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 the any servicing be carried out by a competent
person.

To obtain service, please call your installer or Heatcall (Glow-
worm’s own service organisation) using the telephone number
given on the control 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 1.  Enough space must also be left in front
of the boiler to allow for servicing.

The convection air openings on top of the boiler must never
obstructed.

Boiler 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.

Diagram 1

260mm

100mm

915mm

108mm

6mm

TO
FLOOR

WORKTOP

Additional clearances may

be required for installation

6mm

2166

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
soapy cloth or dry polishing duster.

Do not use an abrasive cleaner.

Boiler Electrical Supply

Warning.  This boiler must be earthed.

The boiler must be connected to a 230V~50Hz supply, protected
by a 3A fuse.

All wiring must be in accordance with the current issue of
BS7671.

Cables, PVC insulated type, to the current issue of BS6500
Table 16, 0.75mm

2

 (24/0.20mm) only may be used to connect

the boiler up.

Summary of Contents for Ultimate 40CF

Page 1: ...ce of mind plus valuable protection against breakdown by covering the cost of Guarantee Registration Open Flue Boiler This is a Cat I2H Appliance BS 6332 BS 5258 Reference in these instructions to British Standards and Statutory Regulations Requirements apply only to the United Kingdom The instructions consist of three parts User Installation and Servicing Instructions which includes the Guarantee...

Page 2: ...uels 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 ...

Page 3: ...n on the control 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 ...

Page 4: ...RMOSTAT CONTROL KNOB C GAS SERVICE COCK SHOWN IN OFF POSITION D CONTROL BUTTON GAS E VIEWING WINDOW F FLUE BLOCKAGE SAFETY DEVICE RESET BUTTON E F B A DATA LABEL Turn thermostat knob B faulty anticlockwise to the O Off position Push in control knob D keep pushed in push and release piezo button A until the pilot lights Look through window E After the pilot burner lights keep the button pushed in f...

Page 5: ...Range Rating The boiler is range rated and may be adjusted to suit the individual system requirements The respective Table 1 gives the ratings and settings A B C D E F H K L M N R S 764 265 168 213 149 24 5 39 115 741 417 640 345 23 MODEL Diagram 1 1 GENERAL DIMENSIONS all dimensions in mm 40CF 0020M B D C H F A R L N GAS CONNECTION RC1 2 1 2 in BSPT WATER CONNECTION RC1 1in BSPT M K E S C L C L F...

Page 6: ...boiler must be mounted on a flat wall which is sufficiently robust to take its weight 1 12 Boiler Clearances Refer to diagram 4 4 The 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 Suffici...

Page 7: ...a cavity wall must be ducted If there are other fuel burning appliances present allowance must be made for their combustion requirements The free area for the boiler is 40CF 38cm2 5in2 Refer also to the current issue of BS5440 Part 2 2 3 Products of Combustion Test the boiler for clearance of flue products at the draught diverter as detailed in the current issue of BS5440 Part 1 2 4 Extract Fans I...

Page 8: ...o C 20o F between flow and return with the boiler thermostat set at MAX which is about 82o C 180o F The resistance through the boiler can be found from diagram 3 3 4 Installation 4 1 Unpacking Unpack and check that the contents listed below are present and undamaged Boiler combustion chamber shield side panels x 2 burner flueway baffle loose items pack with check list With the boiler still in the ...

Page 9: ...e so that the tags on the boiler body locate on the cross member of the wallframe see diagram 4 5 Fasten the boiler to the wallframe using the screws previously removed Remove the flue cleaning door see diagram 4 6 Remove the split pin Withdraw the retaining angle and thermostat phial from its pocket Fit the flueway baffle making sure that it is seated down correctly onto the casing as shown in di...

Page 10: ...fittings Fill vent and cold flush the system as recommended in the current issue of BS6798 Visually check for and put right any water leaks 4 5 Gas Connection Make the gas connection to the flanged Rc1 2 gas service cock 4 6 Flue Installthefluepipeworkandsealtothefluesocketinaccordance with normal practice 5 Electrical Connection 5 2 Cable Connection Thread the mains cable through the clamp at the...

Page 11: ...ntrol knob B to O the off position Remove the gas pressure test nipple screw E and fit a suitable pressure gauge Open gas service cock C Note Make sure that the flue blockage safety device reset button P is fully pushed in Push in control button K keep pressed in and at the same time operate the piezo unit button G until the pilot burner lights After the pilot burner lights keep the button K pushe...

Page 12: ...e cover removed for clarity A ELECTRICAL CONTROL BOX B THERMOSTAT CONTROL KNOB C GAS SERVICE COCK SHOWN IN OFF POSITION D MULTI FUNCTIONAL CONTROL E PRESSURE TEST NIPPLE F GAS BURNER TEST NIPPLE G PIEZO UNIT BUTTON H THERMOCOUPLE PIPE K CONTROL BUTTON GAS M CASE SECURING SCREW N PILOT BURNER PRESSURE SCREW P FLUE BLOCKAGE SAFETY DEVICE RESET BUTTON 8052 E M G B A H P C K D N F Check the operation ...

Page 13: ...ue 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 It is the Law that any servicing must be carried out by a competent person Advise that the boiler is fitted with a safety device and refer to the Instructions for Use Advisetheuseroftheprecautionsnecessarytopreventdamage to the system and ...

Page 14: ...ay baffle ensure they are fitted as shown in diagram 4 6 8 4 Multifunctional Control Servicing Replacement Gain access as Section 8 1 Refer to diagram 6 4 and 8 1 Remove multifunctional control cover securing screw Disconnect the electrical leads thermocouple and pilot supply tube at the multifunctional control Remove the flue blockage safety device securing locknut and release from bracket taking...

Page 15: ...mocouple spring clip and remove the thermocouple Re assembly note When refitting do not tighten the thermocouple nut more than a quarter turn beyond finger tight 8 10 Pilot Burner Gain access as Section 8 1 Refer to diagram 6 3 and 8 4 Remove the main burner as described in Section 8 2 Remove electrode as described in Section 8 7 Disengage the thermocouple spring clip and carefully ease the thermo...

Page 16: ...led up tidily at the rear of the control box There must be no kinks or sharp bends in the capillary 8 12 Peizo Unit Gain access as Section 8 1 Refer to diagram 8 7 Remove the electrical control box refer to Section 5 1 Disconnect the ignition lead at the piezo unit Note To ease the removal of the piezo unit it is advisable to temporarily remove the boiler thermostat from the control box refer to S...

Page 17: ...ple Check aeration If necessary Clean pilot rectify blockage in pilot injector or replace Check thermocouple circuit using Thermocouple fault finding diagram On pressing piezo unit button is there a spark across electrode gap Pull ignition lead off electrode Hold end of lead close to pilot burner and operate piezo unit Is there a spark across gap Pull ignition lead off piezo unit Using blade of a ...

Page 18: ...the flue blockage safety device Is there continuity YES NO NO PERMANENT LIVE 230V 50Hz 3A FUSE THERMOSTAT L RED C NC BROWN MULTI FUNCTIONAL CONTROL SOLENOID BLUE N 3 4 Diagram 9 3 FUNCTIONAL FLOW WIRING 2327 B Diagram 9 2 THERMOCOUPLE FAULT FINDING 9 1 Pilot Refer to chart 9 1 9 2 Thermocouple Refer to chart and diagram 9 2 9 3 Electrical Refer to diagram 9 3 and 9 4 The preliminary electrical sys...

Page 19: ...s available and the pilot is lit Isolate electrical supply to the control box Remove the control box cover and check all cables Turn boiler thermostat to Max Is there continuity between C and NC Turn boiler thermostat to O Is there open circuit between C and NC Faulty thermostat Replace Restore electrical supply with pilot burner lit and boiler thermostat set between MIN and MAX does the main burn...

Page 20: ...Injector 355 274 4 K2674 Thermocouple 390 894 5 K3580 Clip thermocouple 390 983 6 203416 Pilot burner 381 793 7 900500 Spark electrode 381 733 8 WW4617 Ignition lead 312 997 9 202519 Thermostat 381 798 10 204687 Control knob 11 202713 Piezo unit 12 801236 Mica window and foil gasket 13 203350 Solenoid 14 800755 Safety device 278 469 Because of our constant endeavour for improvement details may var...

Reviews: