1. Manuals
  2. Brands
  3. Glowworm Manuals
  4. Boiler
  5. Ultimate 70FF
  6. Installation & servicing instructions manual

Glowworm Ultimate 70FF Installation & Servicing Instructions Manual

Fanned flue boiler
Hide thumbs
Table of Contents

Advertisement

Quick Links

Installation & Servicing Instructions
70FF
G C 4 1 3 1 9 8 6
Reference in these instructions to British Standards Regulations/Requirements apply only to the United Kingdom.
One Contact Total Service
To b e l e f t w i t h t h e u s e r
Fanned Flue Boiler
This is a Cat I
For Ireland the rules in force must be used.
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
80FF
G C 4 1 3 1 9 6 0
Appliance
2H
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
220683B.11.96
BS 6332
BS 5258

Advertisement

Table of Contents
loading

Related Manuals for Glowworm Ultimate 70FF

Summary of Contents for Glowworm Ultimate 70FF

  • Page 1 220683B.11.96 Installation & Servicing Instructions 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 Fanned Flue Boiler BS 6332 This is a Cat I...
  • Page 2 1 G e n e r a l WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) SIDE ELEVATION FRONT ELEVATION MODEL 80FF All dimensions are given in millimetres (except as noted) Diagram 1.1 1.1 Statutory Requirements The instructions consist of two parts, Installation and Servicing Instructions and Instructions for Use, which The installation of the boiler must be carried out by a includes the Guarantee Registration Card.
  • Page 3 1 G e n e r a l 1.2 Data TABLE 2. 70FF See Table 1 and diagram 1.1. RANGE RATING Min. Medium Max. All dimensions are given in millimetres (except as NOMINAL 22.39 24.03 25.64 noted). HEAT INPUT Btu/h 76,400 82,000 87,500...
  • Page 4 1 General 1.4 B.S.I. Certification 1.7 Contents of Packaging This boiler is certificated to the current issue of British The boiler is delivered in one pack, refer to Section 4.1 Standard 6332 Part 1, invoking the current issue of for contents. BS5258 Part 1 for performance and safety.
  • Page 5 1 General 1.12 Boiler Clearances Refer to diagram 1.2. This boiler must be positioned so that at least the minimum operational and servicing clearances are provided. 500mm Additional clearances may be required for installation. If fixtures are positioned next to the boiler they should Additional clearances may be be made removable for access to pipework.

  • Page 6: Terminal Position

    2 F l u e a n d V e n t i l a t i o n Note. Detailed recommendations for flue are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1.

  • Page 7: Frost Protection

    3 W a t e r S y s t e m s The installation of the boiler must comply with the requirements of the current issue of BS6798. 1000 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 8 3 W a t e r S y s t e m s 3.4 Water System OPEN VENTED FULLY PUMPED WATER SYSTEM RECOMMENDED RELATIONSHIP BETWEEN For an open vented system the boiler must be supplied PUMP COLD FEED AND VENT from an unrestricted water supply taken from a feed and 22mm VENT expansion cistern fitted at a maximum height of...
  • Page 9 3 W a t e r S y s t e m s 22mm VENT & 15mm COLD FEED FLOW TO BE FITTED IN 28mm ACCORDANCE RETURN PIPE WITH BS 5449 INDIRECT CYLINDER 1metre Min. ALTERNATIVE BYPASS 22mm 27 metres SYSTEM MIN WITH CONTROL...
  • Page 10 3 W a t e r S y s t e m s 3 LITRES (0.66 gals) MAKE-UP BOTTLE RELEASE (if required) POINT AUTO VENT NON-RETURN VALVE FILLING POINT 22mm (min) BY-PASS WITH LOCKSHIELD VALVE FLOW CIRCULATING SAFETY PUMP VALVE PRESSURE GAUGE RETURN...
  • Page 11 3 W a t e r S y s t e m s 3.12 Pressure Gauge 0051M METHOD 1 COMBINED A pressure gauge with a set pointer and covering at least CHECK VALVE HEATING TEMPORARY the range 0 to 4bar (0 to 60lb/in ) shall be permanently AND VACUUM SYSTEM...
  • Page 12 4 F l u e a n d A p p l i a n c e P r e p a r a t i o n 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 Position and Length Determine flue application, length and terminal position before starting.
  • Page 13 4 F l u e a n d A p p l i a n c e P r e p a r a t i o n 4.3 Flue Preparation All flue assemblies are designed for initial installation, given that there is sufficient clearance opposite to the flue for the installation of the flue.
  • Page 14 4 F l u e a n d A p p l i a n c e P r e p a r a t i o n Reposition the template, making sure of dimensional alignment with the flue hole. Mark the boiler fixing points and mounting bracket position, see diagram 4.6.
  • Page 15 4 F l u e a n d A p p l i a n c e P r e p a r a t i o n LONG FLUE FLUE TERMINAL DUCT STANDARD FLUE TERMINAL Q PLUS 5mm Diagram 4.7 Diagram 4.9 LONG FLUE TERMINAL...

  • Page 16: Flue Assembly - Installation

    4 F l u e a n d A p p l i a n c e P r e p a r a t i o n 4.9 Air Duct/Terminal and Flue Duct Assembly Locate the flue duct into the air duct/terminal, see diagram 4.11.
  • Page 17 4 F l u e a n d A p p l i a n c e P r e p a r a t i o n FOAM SEAL 10mm WALL THICKNESS- UP TO 300mm FOAM SEAL AIR DUCT/TERMINAL FLUE DUCT ASSEMBLY SEALANT...
  • Page 18 5 B o i l e r I n s t a l l a t i o n 5.1 Boiler Preparation CONTROLS With the boiler still in the bottom tray, slide the controls COVER tray upwards and remove it as shown in diagram 5.1. Remove the front cover by undoing (and keeping) the FRONT screw and wing nuts and lifting the front cover off, see...
  • Page 19 5 B o i l e r I n s t a l l a t i o n 5.3 Water Circulation System ELECTRICAL CONNECTIONS Complete the water connections to the boiler. Fill, vent and flush the system. Check for any water leaks and put right. 5.4 Safety Valve Discharge CLEAR PRESSURE...
  • Page 20 5 B o i l e r I n s t a l l a t i o n SCREW SIDE REAR RIGHT dia. drill JUBILEE CLIP LEFT DUCT RIGHT EXTENSION REAR SIDE VERTICAL SEALANT LEFT DUCT EXTENSION SEALANT Cutting 'MARK' lengths. Lefthand flue does not require cutting.
  • Page 21 5 B o i l e r I n s t a l l a t i o n 5.8 Pump Connection FIXING SCREWS The pump must be connected directly to the control box, as shown in diagram 5.9 threading the cable through the cable clamp in the side of the control box.
  • Page 22 6 C o m m i s s i o n i n g 6.1 All Systems Commissioning should be carried out by a competent OVERHEAT person in accordance with the current issue of BS6798. SAFETY CUT OFF Make sure that the system has been thoroughly flushed out with cold water without the pump in place.

  • Page 23: Spark Gap

    6 C o m m i s s i o n i n g Remove the combustion chamber front, see diagram 6.3. WARNING. The fan operates on mains voltage, terminals will become live. Turn the electrical supply on and check that all remote SECURING controls are calling for heat.

  • Page 24: Testing - Gas

    6 C o m m i s s i o n i n g 6.4 Testing - Electrical Turn the control thermostat knob fully anticlockwise to “O”. Remove the pressure gauge from the test point and Turn the boiler thermostat knob fully clockwise to the refit screw, making sure a gas tight seal is made.
  • Page 25 6 C o m m i s s i o n i n g 6.8 Sealed Water Systems ONLY Adjust the system to initial design pressure. The set SEAL pointer on the pressure gauge should be set to coincide with the indicating pointer. SIDE SEAL 6.9 Thermostatic Radiator Valves...
  • Page 26 7 I n s t r u c t i o n s t o t h e U s e r Instruct and demonstrate the safe and efficient operation of the boiler, heating system and domestic hot water system. Advise the user, that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals.
  • Page 27 8 S e r v i c i n g Notes, To ensure the continued efficient and safe SECURING operation of the boiler it is recommended that it is SCREW (4) checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the FLUEHOOD particular installation conditions and usage, but in general once a year should be enough.
  • Page 28 8 S e r v i c i n g 8.3 Main Burner Disconnect the pilot pipe union connector and pilot burner, securing nut and shakeproof washer together with the pilot shield. Remove the pilot burner assembly taking care not to damage the electrode and lead assembly, see diagram 8.3.

  • Page 29: Electrical Supply Failure

    9 F a u l t F i n d i n g 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding Failure of the electrical supply will cause the burner to task which has required the breaking and remaking of go out.
  • Page 30 9 F a u l t F i n d i n g Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated. For fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.

  • Page 31: Fault Finding

    9 F a u l t F i n d i n g Pump overrun Operation The Control Thermostat has a pump overrun facility built into it, when the Control Thermostat is set at maximum only, the pump overrun will keep the pump running to allow the boiler to cool down after which it will stop, providing the remote controls are NOT calling for heat.
  • Page 32 9 F a u l t F i n d i n g bk BLACK w WHITE br BROWN BLUE YELLOW THERMOSTAT PUMP OVERRUN LINK PURPLE PUMP SPARK ELECTRODE FUSE O/H CUTOFF TYPE F1A 1 AMP CONTROL STAT (N/O) PRESSURE SWITCH (N/C) PILOT...
  • Page 33 9 F a u l t F i n d i n g KEY: FULLY PUMPED OPEN - BLUE VENTED OR SEALED bk - BLACK WATER SYSTEM - BROWN g/y - GREEN/YELLOW - RED - YELLOW MULTI-FUNCTIONAL - WHITE CONTROL - PURPLE PRESSURE SWITCH...
  • Page 34 1 0 R e p l a c e m e n t o f P a r t s 10 Replacement of Parts ELECTRICAL CONNECTIONS Note. Replacement of parts must only be carried out by CONTROL BROWN 9 a competent person. THERMOSTAT Before replacing any parts isolate the boiler from the PURPLE 7...
  • Page 35 1 0 R e p l a c e m e n t o f P a r t s 10.4 Control Board (PCB) - diagram 102A 10.5 Pilot Burner and Pilot Injector Release the control box, refer to Section 5.6. Proceed as Section 8.3 and 8.5.

  • Page 36: Electrical Plug

    1 0 R e p l a c e m e n t o f P a r t s 10.12 Viewing Window - diagram 10.5 10.7 Multifunctional Control - diagram 10.3 Remove the push on fixes and then the window. Disconnect the pilot supply by unscrewing the tubing nut at the multifunctional control, take care as there is a When replacing take care not to damage the gasket.
  • Page 37 1 0 R e p l a c e m e n t o f P a r t s SECURING FRONT INSULATION POINTS VIEWING WINDOW RETAINING SCREW GASKET PUSH ON FIX RETAINING PLATE Diagram 10.5 CLEAR AIR PRESSURE SWITCH TUBES SECURING SCREWS SIDE INSULATION...

  • Page 38: Part Identification

    1 1 S p a r e P a r t s 11.1 Part Identification The key number on the diagram and the list will help to identify the part. 11.2 Ordering When ordering any spare parts please quote the number and description from the list together with the model name and serial number.
  • Page 39 1 1 S p a r e P a r t s Diagram 11.1 220683B...
  • Page 40 Control of Substances Hazradous to Health INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER. Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. CERAMIC FIBRE/INSULATION 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.

This manual is also suitable for:

Ultimate 80ff

Table of Contents