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6

221785B

On completion test the gas installation for soundness using the
pressure drop method and suitable leak detection fluid, purge
in accordance with the above Standard.

1.6 Electrical Supply

WARNING:  This boiler must be earthed.

All system components shall be of an approved type and shall
be connected in accordance with the current issue of BS7671
and any applicable local regulations.

Connection of the boiler and system controls to the mains
supply should be through a common isolator fused at 3A,
maximum.  This method of connection should be by a switched
spur box with a minimum contact separation of 3mm in both
poles.  It should be clearly marked, showing its purpose,
preferably positioned close to the boiler.

Alternatively an unswitched socket outlet and three pin plug,
fused 3A, to the current issue of BS1363 may be used.

Wiring to the boiler must be PVC insulated cable at least
0.75mm

2

 (24/0.20mm) to the current issue of BS6500 Table 16.

1.7 Contents of Packaging

The boiler is delivered in one pack which contains:

Boiler with outer case and wall frame, side panels, burner,
combustion chamber shield, flueway baffle and loose items
pack.

1.8 Water System

The boiler shall only be used on an unrestricted open vented
system with the water supply taken from a feed and expansion
tank, having a head between 1m (3ft 3in) minimum and 27m
(90ft) maximum.

1.9 Draining Tap

A draining tap must be provided at the lowest point of the system
which will allow the entire system, the boiler and hot water
cylinder to be drained.

Draining taps shall be to the current issue of BS2879.

1.10 Safety Valve

A safety valve need not be fitted to an open vented system.

1.11 Location

WARNING.  Open flue boilers must not be installed in a private
garage.

The boiler must not be installed in a room used or intended to
be used as sleeping accommodation or a room containing a
bath or shower.

The 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.

Sufficient clearance must be left in front of the boiler for
servicing.

1.13Heating System Controls

The heating system should have installed: a programmer and
room thermostat  controlling the boiler.

Thermostatic radiator valves may be installed in addition to the
room thermostat.

Note: For further information, see The Building Regulations
1991 - Conservation of fuel and power, 1995 edition - Appendix
G, table 4b.

Important Note

The boiler is fitted with a Flue Blockage Safety Device, which
will shut down the boiler if there is an unacceptable spillage of
products at the draught diverter.

This safety device MUST NOT under any circumstances be
interfered with or put out of action.

The safety device must only be replaced with the Glow-worm
parts.

2.1 Flue Connection

The integral draught diverter makes the combustion performance
independent of conditions in the secondary flue, but an efficient
flue is necessary to ensure a trouble free installation.

COMPARTMENT
VENTILATION
REQUIREMENTS

ULTIMATE 40CF

COMPARTMENT AIR VENT TABLE 2.

FROM ROOM
OR SPACE

140cm

2

22in

2

278cm

2

44in

2

70cm

2

11in

2

139cm

2

22in

2

HIGH LEVEL

LOW LEVEL

VENT AREA

VENT AREA

FROM
OUTSIDE

TABLE 1

RANGE RATING

Min.

NOMINAL

kW

HEAT INPUT
(GROSS)

Btu/h

NOMINAL

kW

HEAT
OUTPUT

Btu/h

BURNER

mbar

SETTING
PRESSURE

in.w.g

APPROX.

m

3

/h

GAS
RATE

ft

3

/h

BURNER :- FF2029

PILOT :- 7215

INJECTOR
MARKING

11.69

15.36

39,900

52,400

ULTIMATE 40CF

  RANGE RATING

Max.

8.1

14.2

3.3

5.7

8.79

11.72

30,000

40,000

1.13

1.47

40

52

1 General Data

2 Flue and Ventilation

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...

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