Glow-worm Ultimate 40CF - Manual (Page 11)

11 221785B
5 Electrical Connection
8049 BROWN
BLUE
GRN/YEL
BLUE
BROWN
N E
EARTH
230V~50Hz PERMANENT MAINS
SUPPLY FUSED AT 3 AMP
BLK
THERMOSTAT
NC C
GRN/YEL
BROWN
ELECTRICAL
CONNECTIONS -
BOILER COMPONENTS
Diagram 5.3
L
GRN/YEL
GRN/YEL
MULTI-FUNCTIONAL
CONTROL
BLUE
BLUE
Connect to the terminal strip, as shown in diagram 5.3.
Secure the cable into the clamp, as shown in diagram 5.2.
Make sure that there is sufficient cable to allow the control box
to be temporarily hooked into the front slot, to allow for servicing.
Replace the control box by reversing the information given
above in Section 5.1. Take care not to trap the thermostat
capillary at the rear of the control box also make sure the rear
location hook is correctly engaged.
5.3 Testing
Checks to ensure electrical safety should be carried out by a
competent person.
It is essential that the polarity is correct.
In the event of an electrical fault after installation of the system,
the preliminary electrical system checks, as below should be
carried out:
1. Test insulation resistance to earth of mains cable.
2. Test earth continuity and short circuit of all cables.
3. Switch on the electrical supply to the boiler and test the
polarity of the mains supply.
6 Commissioning
Please ensure the "Benchmark" logbook is completed and left
with the user.
6.1 Testing, Initial Lighting and Adjustment
Make sure that all naked lights, pipes and cigarettes are out.
Pressure test the complete installation for soundness and
purge in accordance with the current issue of BS6891.
Refer to diagram 6.1 to fit the burner.
Identify the controls by reference to diagram 6.2.
Check that the gas service cock “C” is off, that is, indicator
vertical.
Check that the mains electrical supply to the boiler is off.
Set the thermostat control knob “B” to “O” - the off position.
Remove the gas pressure test nipple screw “E” and fit a suitable
pressure gauge.
Open gas service cock “C”.
Note. Make sure that the flue blockage safety device reset
button “P” is fully pushed in.
Push in control button “K”, keep pressed in and at the same time
operate the piezo unit button “G” until the pilot burner lights.
After the pilot burner lights keep the button “K” pushed in for
about 15 seconds. If the pilot burner fails to light or stay alight
a safety device in the multifunctional control prevents immediate
re-lighting.
Do not attempt to relight until the safety device has reset, that
is, after a minimum of 3 minutes.
Note. Should the boiler fail to operate correctly refer to Fault
Finding Section.
Check the length of the pilot flame, it should envelop the
thermocouple tip as shown in diagram 6.3. The pilot rate can be
adjusted, if necessary, by turning the pilot burner adjustment
screw “N”, having first removed the multifunctional control cover
by releasing the screw as diagram 6.4.
Test pilot supply connections for gas soundness, using a
suitable leak
detection fluid.
Hook the combustion chamber shield onto the front of the
combustion chamber, making sure that it is flush and horizontal
with the combustion chamber front, see diagram 6.1.
Fit the outer case, making sure that the lower part clears the pilot
supply tube. Secure with the screws previously removed.
Make sure that the pilot is alight and stable by viewing through
the window in the casing.
Switch on the electrical supply to the boiler and turn on all
external controls.
Set the thermostat knob “B” between “MIN” and “MAX” and
check that the main burner cross lights smoothly from the pilot.
Whilst the boiler is operating test gas valve and gas connections
for gas soundness using a suitable leak detection fluid.