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4098

2000225231B.10.04

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 the Glow-worm Customer

Service number 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

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 force 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.

T o  b e   l e f t   w i t h   t h e   u s e r

Instructions for Use

Installation and Servicing

G.C. No. 41 047 54

REGISTER YOUR GLOW-WORM APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0800 073 2142

40FF

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

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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