Glowworm Ultimate 80FF Installation & Servicing Instructions Manual Download Page 1

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Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: (01773) 824141 Fax: (01773) 820569

One Contact Total Service

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

Installation & Servicing Instructions

220683B.11.96

To b e l e f t w i t h t h e u s e r

70FF

80FF

G C 4 1 3 1 9 8 6

G C 4 1 3 1 9 6 0

4098

Fanned Flue Boiler

Reference in these instructions to British Standards Regulations/Requirements apply only to the United Kingdom.

For Ireland the rules in force must be used.

This is a Cat I

Appliance

BS 6332
BS 5258

Summary of Contents for Ultimate 80FF

Page 1: ...8100 Fax 01773 828070 Installation Servicing Instructions 220683B 11 96 To b e l e f t w i t h t h e u s e r 70FF 80FF G C 4 1 3 1 9 8 6 G C 4 1 3 1 9 6 0 4098 Fanned Flue Boiler Reference in these in...

Page 2: ...ts of applicable British Standards Where no British Standards exist materials and equipment should be fit for their purpose and of suitable quality and workmanship Sheet Metal Parts WARNING When insta...

Page 3: ...m right hand side of case TABLE 2 80FF RANGE RATING NOMINAL kW HEAT INPUT Btu h NOMINAL kW HEAT OUTPUT Btu h BURNER m bar SETTING PRESSURE in w g APPROX m3 h GAS RATE ft3 h Min Medium Max 25 97 27 65...

Page 4: ...be fused 3A maximum This method of connection must be by a fused double pole isolating switch with a minimum contact separation of 3mm on both poles The switch should be readily accessible and prefer...

Page 5: ...r compartment design are given in the current issue of BS6798 The doorway opening should be of sufficient size to allow for easy removal of the boiler Where the boiler is fitted in a cupboard or compa...

Page 6: ...shield 750mm long should be fitted immediately beneath the guttering or eaves 2 2 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could...

Page 7: ...found from diagram 3 1 High resistance microbore systems may require a higher duty pump 3 3 Bypass Fully Pumped and Sealed Water System A bypass MUST be fitted to a fully pumped and sealed water syst...

Page 8: ...the current issue of BS5546 refer also to the current issue of BS6700 3 6 Cylinder For all systems supplying domestic hot water the cylinder must be indirect It is recommended that the cylinder be fi...

Page 9: ...em take special care to drain the entire system including radiators then thoroughly cleaning out before installing the boiler whether or not adding an inhibitor 3 W a t e r S y s t e m s Diagram 3 3 F...

Page 10: ...arge can be seen 3 11 Expansion Vessel A diaphragm type expansion vessel conforming to the current issue of BS4814 see also BS7404 Part 1 and 2 must be connected at a point close to the inlet side of...

Page 11: ...ovision for filling the system at low level must be made Three methods are shown in diagram 3 5 There must be no permanent connection to the mains water supply even through a non return valve 3 16 Wat...

Page 12: ...P WALL TEMPLATE LOOSE ITEMS PACK MOUNTING BRACKET INSTRUCTIONS BOILER 4 1 Unpacking Open the carton check the items supplied against the boiler pack contents list on the flap see diagram 4 1 4 2 Flue...

Page 13: ...rner adjacent surface where the flue is required to exit to outside Mark the position of the centre of the flue and boiler see diagram 4 4 4 5 Flue Hole Cutting Having marked out the flue centre cut a...

Page 14: ...e Duct Mark the duct to the length required this length allows for expansion see diagram 4 7 for rear flue and diagram 4 8 for side flue then cut square and remove any burrs 4 8 Air Duct Terminal Mark...

Page 15: ...iagram 4 10 STANDARD FLUE TERMINAL Q BOILER CENTRE LINE BOILER CENTRE LINE Q T MINUS 188mm Q PLUS 5mm LONG FLUE TERMINAL LONG FLUE TERMINAL STANDARD FLUE TERMINAL FLUE DUCT 4128 4130 4127 4129 4 F l u...

Page 16: ...erminal at the position shown in diagram 4 12 4 11 Wall thickness over 300mm Fit the self adhesive foam seal around the air duct terminal such that when installed the seal will be within the wall slee...

Page 17: ...r a t i o n Diagram 4 12 10mm Q WALL THICKNESS UP TO 300mm Q 25mm Q WALL THICKNESS OVER 300mm FOAM SEAL FOAM SEAL 4132 Diagram 4 11 Diagram 4 13 GASKET PRE ATTACHED WALL SLEEVE 4082 FLUE DUCT 5mm 3mm...

Page 18: ...bly to the boiler using the previously fitted dogpoint screws noting that these are keyhole fixings see diagram 5 5 Make sure of the correct fitting of the flue to the boiler For a side outlet cut the...

Page 19: ...Make the gas connection to the Rc1 2in gas service cock see diagram 6 1 Check for leaks using a suitable leak detection fluid 5 6 Control Box Removal Remove the electrical control box securing screws...

Page 20: ...t to 85o C cable of at least 0 75mm2 24 0 2mm to the current issue of BS6500 Table 16 and of suitable length thread through cable clamps secure into the plastic clips and connect to appropriate termin...

Page 21: ...arried out by a competent person After installation of the system preliminary electrical system checks as below should be carried out 1 Test insulation resistance to earth 2 Test continuity and short...

Page 22: ...et pressure Where this is not possible conduct a manual check and test Release cold water to initial system design pressure The set pointer on the pressure gauge should be set to coincide with the ind...

Page 23: ...sequence The pilot rate is preset and must not be adjusted The step adjustment screw must not be touched The pilot flame length should be as shown in diagram 6 4 Turn the control thermostat knob to O...

Page 24: ...least 10 minutes after the burner has lit making sure that all gas burning appliances and pilot lights are off Neon 4 will light Turn the control thermostat knob fully anticlockwise to O Remove the p...

Page 25: ...rational Checks and Completion Adjust the boiler thermostat and any system controls to their required settings Do not attempt to adjust the thermostat calibration screw Operate the boiler again on ful...

Page 26: ...eral once a year should be enough Draw attention if applicable to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let ou...

Page 27: ...witch on the electrical supply to operate the fan and turn the gas supply on On completion of the test switch off the electrical supply and the gas supply and reconnect the red tube to the air pressur...

Page 28: ...rner removed the main injector can be inspected 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...

Page 29: ...he rest button on the front of the control box see diagram 6 1 If the cutoff operates at any other time press the rest button and the burner should relight If the fault persists refer to fault finding...

Page 30: ...etween yellow connection on overheat device and N YES Is there 240V between motor connections on fan YES Isolate electrical supply test fan harness continuity If satisfactory replace printed circuit b...

Page 31: ...n in order NO NO Faulty pump wiring Replace or repair as necessary Is there 240V on 9 connection on thermostat Is there 240V on P for pump Faulty connections between thermostat and terminal strip Repa...

Page 32: ...r y y y r b r bk b y br b b bk b KEY bk BLACK br BROWN b BLUE w WHITE r RED y YELLOW SL MAIN TERMINAL STRIP CONNECTIONS CONTROL THERMOSTAT CONNECTIONS PRINTED CIRCUIT BOARD CONNECTIONS FULLY PUMPED OP...

Page 33: ...between 9 and SL when fitting a time control etc If no switch is fitted link will make the circulation pump run constantly CHASSIS EARTH L N CIRCULATION PUMP E E N L 240 50Hz PERMANENT MAINS SUPPLY FU...

Page 34: ...body Release the thermostat body by unscrewing the two screws and shakeproof washers in the front of the control box Remove the split pin and withdraw the thermostat phial from its pocket Release the...

Page 35: ...6 Electrode Proceed as Section 8 3 and 8 5 Gain access as Section 5 6 to remove lead from control box Diagram 10 2 Diagram 10 2A 1 0 R e p l a c e m e n t o f P a r t s PHIAL POCKET THERMOSTAT PUMP O...

Page 36: ...ain injector as Section 8 4 10 11 Insulation 10 4 Combustion Chamber Front Remove the retaining screw then the insulation Sides Slide the insulation out Rear With the side insulation removed the rear...

Page 37: ...E SWITCH TUBES ELECTRICAL CONNECTIONS CONTROL BOX FRONT INSULATION RETAINING SCREW SIDE INSULATION REAR INSULATION AIR PRESSURE SWITCH PUSH ON FIX RETAINING PLATE GASKET VIEWING WINDOW SECURING POINTS...

Page 38: ...S p a r e P a r t s 1 800442 Multifunctional control 278 021 2 208040 O ring 334 592 3 205710 Injector 80FF 278 024 3 205701 Injector 70FF 313 393 4 203432 Pilot burner 278 023 5 411194 Sight glass 3...

Page 39: ...39 220683B 1 1 S p a r e P a r t s Diagram 11 1 4 6 2 1 9 10 5 7 8 11 3 13 14 15 4119...

Page 40: ...handling should not cause discomfort but follow normal good hygiene and wash your hands before eating drinking or going to the lavatory If you do suffer irritation of the eyes or severe irritation to...

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