Glowworm Ultimate 60FF Instructions For Use Installation And Servicing

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this manual

Installation and Servicing

60FF

G.C. No. 41 047 15

Fanned Flue Boiler

(SIT)

This is a Cat II

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, which includes the Guarantee Registration

Card. 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.

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

In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and

If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer

Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:

All replacement parts

All labour charges

All call-out charges

One Contact Local Service

Instructions for Use

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

BS 6332

BS 5258

Appliance

2H3P

Guarantee Registration

to offer our customers' a Comprehensive First Year Guarantee.

return as soon as possible.

Service number 01773 828100.

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

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

221521F.04.01

Table of Contents

Need help?

Do you have a question about the Ultimate 60FF and is the answer not in the manual?

Questions and answers

Summary of Contents for Glowworm Ultimate 60FF

Page 1 221521F.04.01 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 60FF G.C. No. 41 047 15 Fanned Flue Boiler (SIT) BS 6332 BS 5258 This is a Cat II Appliance 2H3P Reference in these instructions to British Standards and Statutory...
Page 2: Table Of Contents
Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
Page 3 Instructions for Use Introduction To obtain service, please call your installer or Heatcall (Glow- worm’s own Service Organisation) using the telephone number WARNING. It is important that the case (not the controls tray) given on the controls tray. is not disturbed or removed other than for servicing by a Please be advised that the ‘Benchmark’...
Page 4 Instructions for Use Cleaning To Light the Boiler WARNING. This appliance contains metal parts (components) WARNING. Sealed Systems and care should be taken when handling and cleaning, with A sealed water system must be filled and pressurised by a particular regard to edges. competent person.
Page 5: General Data
1 General Data WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) All dimensions are given in millimetres (except as noted) SIDE ELEVATION FRONT ELEVATION Diagram 1.1 Detailed recommendations are contained in the current issue of Important Notice the following British Standards and Codes of Practice:- This boiler is for use only on natural gas (G20), but may be BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, converted for use on L.P.G.
Page 6 1 General Data 1.5 Gas Supply 1.6 Electrical Supply The gas installation shall be in accordance with the current WARNING. This boiler must be earthed. issue of BS6891. All system components shall be of an approved type and shall The supply from the governed meter must be of adequate size be connected in accordance with the current issue of BS7671 to provide a steady inlet working pressure of 20mbar (8in wg) at and any applicable local regulations.
Page 7 1 General Data 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. Additional clearances may be required for installation. 500mm If fixtures are positioned next to the boiler they should be made removable for access to pipework.
Page 8: Flue & Ventilation
2 Flue and Ventilation Note: Detailed recommendations for flues 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. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.
Page 9: Water Systems
3 Water Systems 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 10 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 22mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION CISTERN 1150mm MIN. PUMP 22mm VENT & 15mm COLD FEED TO BE FITTED IN ACCORDANCE There must always WITH BS 5449...
Page 11 3 Water Systems 3.12 Expansion Vessel 3.13 Pressure Gauge A diaphragm type expansion vessel, conforming to the current A pressure gauge with a set pointer and covering at least the issue of BS4814 (see also BS7074 Part 1 and 2) must be range of 0 to 4bar (0 to 60lb/in ) shall be permanently fitted to connected at a point close to the inlet side of the circulating...
Page 12 3 Water Systems 3.16 Filling a Sealed Water System 0051M METHOD 1 COMBINED Provision for filling the system at low level must be made. Three CHECK VALVE HEATING methods are shown in diagram 3.6. There must be no permanent TEMPORARY AND VACUUM SYSTEM connection to the mains water supply, even through a non-...
Page 13: Flue And Appliance Preparation
4 Flue and Appliance Preparation 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 terminal position before starting. Refer to diagram 4.2 or 4.3.
Page 14 4 Flue and Appliance Preparation 4.3 Flue Preparation All flue assemblies are designed for internal installation (optional wall liner is required), given that there is sufficient clearances opposite to the flue for the installation of the flue. 115mm If there is insufficient clearance the flue can be installed from MINIMUM outside.
Page 15 4 Flue and Appliance Preparation 4.5 Flue Hole Cutting Having marked out the flue centre cut a hole for the flue using, preferably, a 115mm minimum core drill. 4.6 Wall Mounting Bracket Reposition the template, making sure of dimensional alignment with the flue hole.
Page 16 4 Flue and Appliance Preparation 4.8 Air Duct/Terminal Mark the duct length, see diagram 4.8 for rear flue and diagram 4.9 for side flue, then cut square and remove any burrs. 4.9 Air Duct/Terminal and Flue Duct Assembly Locate the flue duct into the air duct/terminal, see diagram 4.10. Take the flue manifold from the loose items pack together with the sealant.
Page 17 4 Flue and Appliance Preparation Important: If the wall liner kit is used the self adhesive foam seal included in the wall liner kit must be used in place of the one supplied with the flue pack, see diagram 4.11 for position of self adhesive seal.
Page 18: Boiler Installation
5 Boiler Installation 5.1 Boiler Preparation With the boiler still in the bottom tray, slide the controls cover CONTROLS upward and remove it as shown in diagram 5.1. COVER Remove the front cover by undoing the wing nut, nut and washer, lift the front cover off, see diagram 5.1.
Page 19 5 Boiler Installation 5.3 Water Circulation System The mains cable outer insulation must not be cut back external to the cable clamp. Complete the water connections to the boiler. Make sure the cable is suitably secured. Fill, vent and flush the system. When making connections, make sure that the earth conductor Check for any water leaks and put right.
Page 20 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 GASKET BLANKING (REAR FLUE OUTLET ILLUSTRATED) PLATE NUT (3) FLUE...
Page 21 5 Boiler Installation 5.10 External Controls Make sure that the supply cable and all external cables are SECURING secured and away from hot surfaces. SCREWS (2) GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING, SEE DIAGRAM 5.9. FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS, SEE DIAGRAM 5.10.
Page 22: Commissioning
6 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. 6.1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
Page 23 6 Commissioning Turn the control thermostat knob to “O” and isolate the boiler from the electrical supply. Fit the combustion chamber front. Reconnect the ignition lead to the PCB. SECURING Stick the self adhesive arrow indicator to the data label, against SCREW (4) the rating that the boiler is going to be set to, for future reference.
Page 24 6 Commissioning Turn the control thermostat knob fully anticlockwise to “Off”. Remove the pressure gauge from the test point and refit screw, SEAL making sure a gas tight seal is made. When the control thermostat is turned to the “Off” position, by SIDE hand, wait at least 30 seconds before turning “On”...
Page 25: Instructions To User
7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the Section 35, which imposes a duty of care on all persons who let boiler, heating system and domestic hot water system. out any property containing a gas appliance. Advise the user, that to ensure the continued efficient and safe It is the Law that servicing is carried out by a competent person.
Page 26 8 Servicing Remove the main burner from the main injector at the rear. Raise the burner up and forward, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot burner assembly. Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly, making sure that all the burner ports are clear and unobstructed.
Page 27: Fault Finding
9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on the restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
Page 28 9 Fault Finding 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 29 9 Fault Finding 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. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
Page 30 9 Fault Finding bk BLACK or ORANGE bk BLACK or ORANGE br BROWN w WHITE br BROWN w WHITE BLUE BLUE PURPLE y YELLOW PURLPLE YELLOW Red Link must be fitted between SL and 9. RED LINK LINK SPARK ELECTRODE PUMP SPARK ELECTRODE...
Page 31 9 Fault Finding KEY: GRAVITY DOMESTIC - BLUE HOT WATER AND bk - BLACK PUMPED CENTRAL - BROWN HEATING g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE SWITCH CHASSIS CHASSIS EARTH EARTH SEQUENCE Yellow link fitted to bridge out the...
Page 32 9 Fault Finding KEY: FULLY PUMPED - BLUE OPEN VENTED bk - BLACK OR SEALED - BROWN WATER SYSTEM g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE Remove red link between SWITCH 9 and SL when fitting a time control etc (If no switch is fitted,...
Page 33: Replacement Parts
10 Replacement of Parts Note. Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT SHAKEPROOF Before replacing any parts isolate the boiler from the electrical WASHERS AND supply and turn the gas supply off at the gas service cock, SCREWS indicator slot to be vertical.
Page 34 10 Replacement of Parts ELECTRICAL PLUGS PHIAL RETAINING BOILER BRACKET THERMOSTAT SECURING ELECTRICAL SCREW CONNECTION NO.3 "YELLOW" OVERHEAT CABLE CUTOFF DEVICE PHIAL CHASSIS CONTROL EARTH THERMOSTAT CONNECTION PHIAL SUPPORT SECURING EARTH POST (4) SCREW (2) CONNECTION IGNITION SPLIT MAIN LEAD TERMINAL STRIP PLASTIC...
Page 35 10 Replacement of Parts 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 8.3. RESTRICTOR 10.10 Main Injector EXTENDED Remove the main burner as Section 8.3.
Page 36 10 Replacement of Parts 10.11 Insulation - diagram 10.5 Combustion Chamber Front Remove the retaining screw then the insulation. Sides Slide the insulation out. Rear With the side insulation removed 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.
Page 37 10 Replacement of Parts 10.13 Air Pressure Switch - diagram 10.7 Release the control box as Section 5.6. MICA WINDOW Remove the air pressure tubes and electrical connections from the PCB, release the screws and remove the switch. When fitting the replacement make sure that the plastic tubes are fitted as shown in diagram 10.7 and that electrical connections are made as shown in diagrams 9.6 or 9.7.
Page 38: Spare Parts
11 Spare Parts 11.1 Part Identification 11.2 Ordering The key number on the diagram and the list will help to identify When ordering any spare parts please quote the number and the part. description from the list together with the model name and serial number.
Page 39 11 Spare Parts Diagram 11.1 221521F...
Page 40 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221521F...

Glowworm Ultimate 60FF Instructions For Use Installation And Servicing

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Glowworm Ultimate 60FF

Summary of Contents for Glowworm Ultimate 60FF

Table of Contents