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3

2000225231B

4140

Diagram 1

4625

CONTROLS COVER

DATA &
SERIAL
NUMBER
LABEL

RESET
BUTTON

VIEWING WINDOW

SETTING POINT

CONTROL
THERMOSTAT
KNOB

GAS SERVICE
COCK (Shown
Off)

Instructions for Use

Introduction

WARNING:

  It is important that the case (not the controls tray)

is not disturbed or removed other than for servicing by a

competent person

.

The user shall not interfere with or adjust sealed parts.

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

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

The boiler is fully automatic in operation having only one user
control, the control thermostat.

The Gas Safety (Installation and Use)
Regulations

In your interest and that of gas safety it is the law that ALL gas
appliances are installed by a 

competent person

 in accordance

with the above regulations.

Gas Leak or Fault

Turn off the gas emergency control valve immediately. Eliminate
all sources of ignition, i.e.smoking, blowlamps, hot air guns etc.
Do not operate electrical lights or switches either on or off. Open
all doors and windows,ventilate the area.

Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out.
Should this occur, operation of the appliance will normally
resume after the electrical supply is restored.

If the boiler does not relight after an electrical supply failure the
overheat safety cutoff device may need resetting, remove the
controls cover and press the reset button, refer to diagram 1.

Overheat Safety Cutoff

If the overheat safety cutoff device operates on any other
occasion than an electrical supply failure, press the reset button
as in “Electrical Supply Failure”.  If the overheat operates again,
turn the appliance off and contact your installation/servicing
company.

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 in the UK there
is a duty or 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 that any servicing is carried out by a 

competent

person

.

To obtain service, please call your installer or Glow-worm’s own
Service Organisation using the telephone number given on the
controls 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 2.  At least a minimum clearance of 500mm
must be left in front of the boiler to allow for servicing.

Boilers 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.

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 cloth
or dry polishing duster.

Do not use an abrasive cleaner.

Summary of Contents for Ultimate 40FF

Page 1: ...iler 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 For Ireland the rules in f...

Page 2: ...N PADS These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be susceptible to irritation High dust levels are usual only if the material is...

Page 3: ...the reset button as in Electrical Supply Failure If the overheat operates again turn the appliance off and contact your installation servicing company Maintenance To ensure the continued efficient and...

Page 4: ...l of water consult your installation servicing company ALL SYSTEMS Turn the electrical supply on to the boiler and check that all remote controls are calling for heat To Turn the Boiler On Remove the...

Page 5: ...The manufacturer s instructions supplied The Gas Safety Installation and Use Regulations The appropriate Buildings Regulations either The Building Regulations The Building Regulations Scotland The Bu...

Page 6: ...or and must be fused 3A maximum This method of connection must be by a fused doublepoleisolatingswitch withaminimumcontactseparation of 3mm on both poles The switch should be readily accessible and pr...

Page 7: ...pipework At least a minimum clearance of 500mm must be left in front of the boiler for servicing see diagram 1 3 1 13 Room Ventilation The boiler is room sealed and does not require the room or space...

Page 8: ...those detailed in I S 813 Domestic Gas Installations The terminal must be exposed to the external air the position allowing free passage of air across it at all times Car ports or similar extensions...

Page 9: ...vent are as shown in diagram 3 2 The unrestricted open vent from the boiler must rise continuously to discharge over the feed and expansion cistern 3 5 Domestic Hot Water System General All domestic...

Page 10: ...H LOCKSHIELD VALVE FLOW RET There must always be a cold water path to the return connection of the boiler PUMPED RETURN PUMPED FLOW 4124 Diagram 3 4 1metre Min 27 metres Max 22mm VENT 15mm COLD FEED T...

Page 11: ...em design pressure of 0 7bar the minimum total vessel volume required is 0 063xTotal System volume NOTE Ahigherinitialdesignpressurerequiresalargervolume expansion vessel The charge pressure must not...

Page 12: ...BREAKER PRESSURE REDUCING VALVE 0051M Diagram 3 6 3 16 Filling a Sealed Water System Provision for filling the system at low level must be made Three methodsareshownindiagram3 6 Theremustbenopermanen...

Page 13: ...ILER 4 1 Unpacking Open the carton check the items supplied against the boiler pack contents list on the flap and diagram 4 1 4 2 Flue Position and Length Determine flue application length and termina...

Page 14: ...ptionalwalllinerkitisusedthefluecan be fully installed from the inside For a wall thickness of over 300mm the external flue hole will need to be made good from the outside This applies also if you use...

Page 15: ...ram 4 5 Drill holes and plug to suit No 12x2in wood screws fit the screws allowing sufficient clearance about 5mm to accept the swing brackets see diagram 4 5 Secure the mounting bracket to the wall w...

Page 16: ...ue manifold secure with the two self tapping screws supplied in the loose items pack It should now not be possible to remove the manifold 4 10 Rear Fitting Fit the self adhesive foam seal provided in...

Page 17: ...iler is not to be fitted for some time cover the hole in the wall On limited access installations push the flue assembly into the hole such that it is within the wall and does not stick out into the r...

Page 18: ...m the fan see diagram 5 4 Break the air pressure switch tube connections see diagram 5 4 Remove the fan assembly by removing the screws at the front slackening the screws at the rear and sliding it ou...

Page 19: ...oiler must be earthed Take care not to damage any internal wiring and capillaries Take the plastic cable retaining clip from the loose items pack peel off the backing paper and position it in a suitab...

Page 20: ...TRATED VERTICAL REAR RIGHT LEFT SCREW 2 JUBILEE CLIP Cutting MARK lengths Lefthand flue does not require cutting SIDE LEFT FAN DUCT EXTENSION SIDE RIGHT REAR FLUE ELBOW FAN DUCT EXTENSION FAN DUCT EXT...

Page 21: ...INS SUPPLY FUSED AT 3 AMP g y E N K1 K2 PN g y CHASSIS EARTH br b r P SWITCH CONTROL TIME SWITCH PROGRAMMER ETC when fitted remove red link br b L E N CIRCULATON PUMP Any external controls must only b...

Page 22: ...control thermostat is turned to O the Off position Turn the gas service cock On see diagram 6 1 Testthepilotsupplytubeanditsconnectionsforgassoundness as follows Disconnect the ignition lead from the...

Page 23: ...pen refer to fault finding Section 9 1 4 To carry on turn the gas service cock On see diagram 6 1 When the boiler switches Off both the pilot and main burner go out The automatic lighting sequence wil...

Page 24: ...n UNDER NO CIRCUMSTANCES SHOULD THIS VALVE BE LEFT IN THE FULLY CLOSED POSITION 6 8 Sealed Water Systems ONLY Adjust the system to initial design pressure The set pointer on the pressure gauge should...

Page 25: ...n the particular installation conditions and usage but in general once a year should be enough It is the Law that any servicing is carried out by a competent person Before servicing turn off the gas a...

Page 26: ...ected and cleaned as necessary see diagram 8 5 If removing for cleaning do not use a wire or sharp instrument on the hole Use a little suitable sealant on the external thread when refitting to make su...

Page 27: ...tinuity polarity short circuit and resistance to earth checks must be repeated using a suitable multimeter Refer to neon indicators An Aid to Fault Finding diagram 9 1 Boiler Fault Finding diagram 9 2...

Page 28: ...oard With pilot lit does spark stop Isolate supply test harness and replace as required Is there 230V between main multi functional control solenoid black and blue cables YES Replace multi functional...

Page 29: ...is applied 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 Bef...

Page 30: ...if no switch is fitted link will make the circulation pump run constantly F1 F2 or or or p Diagram 9 4 Diagram 9 5 FUSE TYPE F1 F2 F1A SPARK ELECTRODE O H CUTOFF CONTROL STAT FAN AIR PRESSURE SWITCH P...

Page 31: ...ntral heating system remote controls and not to control box Yellow link fitted to bridge out the overheat cutoff b g y E N g y K1 K2 ELECTRODE PN 5859 GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEA...

Page 32: ...AT 3 AMP N E N g y br CIRCULATON PUMP L r See Note SL P PN FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEM 5860 b N b br b MULTI FUNCTIONAL CONTROL br b Remove red link between 9 and SL when fitting a...

Page 33: ...roof washers in the front of the control box Remove the split pin and withdraw the thermostat phial from its pocket Releasethecapillaryfromthebaseandplasticretaining clip then remove it from the split...

Page 34: ...control thermostat and earth connection Release the main terminal strip and plastic label Carefully pull the board away from its supports When refitting refer to wiring diagram 9 6 or 9 7 as appropria...

Page 35: ...ts 10 8 Solenoid diagram 10 3 Remove the electrical plug from the multifunctional control Remove the securing screw and then the solenoid Assembly 10 9 Main Burner Remove the main burner as Section 8...

Page 36: ...emoved the rear insulation can be removed and replaced 10 12 Viewing Window diagram 10 6 Remove the old self adhesive aluminium foil gasket and the old mica window Replace with a new mica window Peel...

Page 37: ...e sure that the plastic tubes arefittedasshownindiagram10 7andthatelectricalconnections are made as shown in diagrams 9 6 or 9 7 10 14 Fan diagram 5 4 Remove the electrical connections and disconnect...

Page 38: ...C number of the appliance and part Key No Part No Description GC Part No 1 203374 Multifunctional control 2 208040 O ring 334 592 3 205708 Injector 40FF 313 944 4 203431 Pilot burner 379 204 5 2000801...

Page 39: ...39 2000225231B Diagram 11 1 5861 1 2 6 4 5 10 9 8 7 11 13 14 15 3 11 Spare Parts...

Page 40: ...40 2000225231B Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions...

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