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Potterton Kingfisher Mf CFL40 - 100, Installation & Service Instructions Manual

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Potterton Kingfisher Mf CFL40 - 100 Installation & Service Instructions Manual Download Page 1

About the Boiler

See inside cover for models covered by these instructions.
This Floor Mounted Fan Assisted Gas Boiler is available as Conventional or Balanced Flue.
This boiler is for use with Natural Gas (G20) only at 20mbar and for use in GB & IE.

About Safety

The Gas Safety (Installation and Use) Regulations 1998.

‘‘ In your own interest, and that of safety, it is law that all gas appliances are installed by competent
persons, in accordance with the above regulations. Failure to install appliances correctly could
lead to prosecution.’’

Installation must be in accordance with the Installation & Service Instructions and the rules in
force.

Leave these instructions and the Benchmark Log Book with the user for use on future calls.

Installation & Service Instructions

Kingfisher Mf

RSL40 - 100, CFL40 -100

CON0005A

TM

The code of practice for the installation,

commissioning & servicing of central heating systems

Summary of Contents for Kingfisher Mf CFL40 - 100

Page 1: ...andthatofsafety itislawthatallgasappliancesareinstalledbycompetent persons in accordance with the above regulations Failure to install appliances correctly could lead to prosecution Installation must be in accordance with the Installation Service Instructions and the rules in force LeavetheseinstructionsandtheBenchmarkLogBookwiththeuserforuseonfuturecalls Installation Service Instructions Kingfish...

Page 2: ...ns are Kingfisher Mf CFL 40 G C No 41 590 24 Kingfisher Mf CFL 50 G C No 41 590 28 Kingfisher Mf CFL 60 G C No 41 590 29 Kingfisher Mf CFL 70 G C No 41 590 30 Kingfisher Mf CFL 80 G C No 41 590 31 Kingfisher Mf CFL 90 G C No 41 590 32 Kingfisher Mf CFL 100 G C No 41 590 34 Kingfisher Mf RSL 40 G C No 41 590 35 Kingfisher Mf RSL 50 G C No 41 590 36 Kingfisher Mf RSL 60 G C No 41 590 37 Kingfisher M...

Page 3: ... 2 m Gas Supply Pressure 20mbar Gas Supply Connection Rc in BSP Female MaximumFlowTemperature 82 C FlowConnection 28 mm Copper Return Connections Gravity 28 mm Copper ReturnConnections Pumped 28 mm Copper WaterContent 6 5 litres Appliance Weight Installed Dry 65 0 kg RSL 69 0 kg CFL Electricity Supply 230v 50Hz Fused at 3A InternalFuse Type 2 AT 2 off PowerConsumption 80 Watts excluding pump Class...

Page 4: ...Data Fig 2 CON0078B CFL Flue Outlet Shown 127 or 153 Outlet CFL Flue Outlet Shown Two Centres Available RSL Flue Outlet Shown RSL Flue Outlet Shown 25 Front Clearance 400 recommended for servicing if non removable 50 100 model shown 103 ...

Page 5: ...der the Consumer Protection Act 1987 and Section 6 of the Health and Safety at Work Act 1974 we are required to provide information on substances hazardous to health Small quantities of adhesives and sealants used in the product are cured and present no known hazards The following substances are also present Insulation and Seals Material Man Made Mineral Fibre Description Boards Ropes Gaskets Know...

Page 6: ...ble material A metal sleeve should be installed to surround the flue duct to provide a 25mm annular space Further guidance is given in BS5440 1 2000 sub clause4 4 If the boiler is to be installed in a timber framed building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 also British Gas Service publication Part 19 Building and Kitchen Work If in doubt ...

Page 7: ...two air vents refer to BS 5440 Part 2 Where an extraction fan is fitted in the room containing the boiler special ventilation requirements must be implemented Refer to BS 5440 Part 2 Any grille and or duct should be so sited and of a type not to become easily blocked or flooded and should offer low resistance to airflow If the boiler is installed in a compartment permanent air vents are required i...

Page 8: ...mm fluesizeshouldbeusedirrespectiveoftheboilersize Horizontal runs should be avoided however if a near horizontal flue run is unavoidable the total vertical height necessary should be calculated in accordance with BS 5440 1 If an existing chimney is used ensure that it is thoroughly swept before lining or connecting the boiler The liner must have an internal diameter of 100mm for the 40 to 60 mode...

Page 9: ...lue Systems Terminal Location Horizontal Concentric Left Right or Rear The flue terminal assembly supplied is suitable for a wall thickness of between 150mm and 400mm Aflue terminalassemblysuitableforawallthicknessof up to 600mm is also available Both the flue terminal assemblies are telescopic and the minimum lengths 150 mm 6 in are achieved by cutting A1mflueextensionisavailable Undernocircumsta...

Page 10: ... window etc B Above an opening air brick opening window etc C Horizontally to an opening air brick opening window etc D Below a gutter or sanitary pipework E Below the eaves F Below a balcony or carport roof G Above ground roof or balcony level H From vertical drain soil pipe work J From an internal or external corner K From a surface facing a terminal L Vertically from a terminal on the same wall...

Page 11: ...t down thus preventing nuisance operation of the overheat thermostat If a three port diverter valve is used as shown in Figs 8 9 a by pass is not necessary since one circuit is always open Where a pair of two port valves are used a by pass is necessary It should be fitted with a lockshield valve and be adjusted to maintain a minimum flow through the boiler of 4 5 litres min 1 gal min see Figs 8 9 ...

Page 12: ...kW of system output Micro Bore Pipework 7 litres Steel Panel Radiators 8 litres per kW of system output Low Water Capacity Radiators 2 litres per kW of system output Hot Water Cylinder 2 litres If the system is extended the expansion vessel volume mayhavetobeincreasedunlessprovisionhasbeenmade for extension Where a vessel of the calculated size is not available the next available larger size shoul...

Page 13: ...Publication No 5102977 13 CON0093B Installation Requirements Fig 8 Fig 7 ...

Page 14: ...Publication No 5102977 14 Installation Requirements Fig 9 Fig 10 ...

Page 15: ... ensure where required the top cover touches the wall This sets the minimum rear clearance for the pipework Mark the position on the floor 4 Remove the plinth 2 screws 5 Remove the front door 2 screws unhook and lift off 6 Remove the controls panel open flap remove screw unhook disconnect the in line connector and lift away 7 Remove the top cover 2 screws pull forward and lift off Installation Fig...

Page 16: ... flue spigot from the appliance by removing the 4 adjusting screws 4 Mark the centre of the flue on the work top and cut a 200 mm square hole from this centre point The centre point should be a minimum of 85 mm from the wall and a maximum of 135 mm from the wall being dependent on the boiler position 5 Place boiler in position under the work top 6 Re fit the flue spigot as shown in Fig 13 7 Refit ...

Page 17: ...model 1 4 m 100model 1 0 m These are for rear or side flue applications see Page 17 Fig 16 3 DeterminedimensionX 20mmSeeFig 13 4 Extendtelescopicfluetotherequiredlength minimum 20 mm overlap 5 Drill through the pilot hole and secure with a self tapping screw 6 Wraptapearoundthejointontheouterduct tosealtheflue slidedripringintopositionto coincide with the air gap in the wall cavity 7 Slide the flu...

Page 18: ...wn in the Maximum Flue Length Guide If an in line bend is required in the flue the following rules apply A 90 in line bend is equivalent to a 1m length of flue A 135 in line bend is equivalent to a m length of flue The maximum equivalent flue resistance allowed when using bends is 40 70 models 3 4 m 80 model 2 4 m 90 100 models No bends allowed Note Forfluelengthslessthantheminimum telescopic leng...

Page 19: ...use of an O ring therefore some pipe movement will be evident even though a water tight seal has been achieved Excessive force is not necessary and could result in damage to the appliance 1 Connectsystempipeworktotheboiler compressionfittingsshouldbeused Arrangepipeworktoensurecorrectventing of pipes and boiler On gravity systems a tee is required in the flow which must be fitted directly to the c...

Page 20: ... to Pump L N E on the terminal block 2 Where no integral programmer is fitted connect the wires as follows GravityDHW PumpedCHSystems a FitalinkbetweenterminalsMAINS SwL and MAINS L b SwitchedlivefromexternalgravityDHW control circuit to MAINS SwL c Neutral to MAINS N d Earth to MAINS E e The pump should be wired externally Fully Pumped Systems a Permanent live to terminal MAINS L b Switched live ...

Page 21: ... clamps to allow the control panel to hinge freely Check by opening the control panel Iffittingtheoptionalintegralprogrammergo to section 2 6 before performing steps 4 and 5 below 4 Securethecontrolsassemblytothechassis using the screw previously removed 5 Carry out preliminary electrical system checks i e Earth Continuity Short Circuit Polarity and Resistance to Earth FrostThermostat If a Frost T...

Page 22: ...ettes pipes etc Important The commissioning and boiler adjustment must only be carried out by a suitably qualified person Potterton offer this service on a chargeablebasis Fig 22 Top Cover RSL Model shown Flue Elbow RSL Model shown CON0079B Important State of adjustment Check that the state of adjustment given on the data plate is compatible with local supply conditions ...

Page 23: ...hort Circuit Polarity Resistance to Earth 10 Switch On the main electricity supply at the isolating switch or plug and socket 11 IfaprogrammerisfittedsetbothDHW CHto the On position and check that the room and cylinder thermostats where fitted are set to hightemperatures 12 The fan will be energised and after a short period the automatic spark will light the pilot When the pilot flame is establish...

Page 24: ...sembly repeated shutdown by this device should be investigated further and fault eliminated OtherBoilerControls No further setting or checking is necessary as allboilermountedcontrolsaredesignedsothat if a fault should occur they will fail safe ExternalControls Check that any other external controls connected in the system such as clocks or thermostats are correctly set and control the boiler as r...

Page 25: ...k Fluegasanalysispointsareprovidedasfollows RSLModels eithersideoftheflueelbow CFLModels ontheFlueSpigot remember to swing the TTB back after the test It is recommended that the flue gas probe is inserted so the tip is halfway into the flue so an accurate reading can be obtained Notes on Cleaning Boiler Components Heat Exchanger After performing operations 4 1 4 6 4 8 place a sheet of paper under ...

Page 26: ...al or replacement of any gas carrying component a test for gas soundnessmustbemadeandfunctionalcheck of the controls carried out Re assemble all parts in reverse order 1 Remove the plinth 2 screws 2 Remove the front cover 2 screws lower and lift away 3 Remove the controls panel open flap remove screw unhook disconnect the in line connector and lift away 4 Remove the top cover 2 screws pull forward...

Page 27: ...see 4 1 Note 5 2 Note the wire connections and disconnect the wires to the air pressure switch 3 Remove the screws securing the air pressure switch to the bracket 4 Note the tube connections and remove the tubes from the switch 5 Re assemble in reverse order 4 4 Temperature Sensor Gain General Access See 4 1 1 Disconnect the wires from the sensor 2 Depress the clips on the outside of the sensorand...

Page 28: ...ve 3 Remove the combustion chamber cover 2 screws 4 Remove the gas valve burner assembly 2 screws 5 Pull the assembly forwards and remove the electrode as follows Hold the electrode wire push in and pull down at the same time and the electrode will disconnect itself 6 Remove pilot tube from valve and pilot 7 Disconnect the gas valve from the burner 3 screws Use a new O ring on re assembly 8 Re ass...

Page 29: ...emove the securing screw and carefully pull the fan down and away from the boiler 4 Remove the fluehood 2 screws and withdraw it from the boiler 5 Fluehood On re assembly check the seal onthefluehoodandreplaceifdamagedand ensure that the fluehood locates under the bracket at the rear of the chassis 6 Fan On re assembly check the seal on the faninletandreplaceifdamaged ensurethat the rubber seal ar...

Page 30: ...Publication No 5102977 30 5 Wiring Diagrams Functional Wiring Diagram Fig 29 Air Pressure Switch CON0089A ...

Page 31: ...Publication No 5102977 31 Fig 30 Pictorial Wiring Diagram CON0082B T T B CFL Models Only ...

Page 32: ...ork check the following Electrical Plugs PL1 to PL6 are to remain connected to the Circuit Board for Fault Finding checks ALL Electrical Power to the Heating System OFF NO External Call for Heat Thermostat Programmer OFF Boiler Temperature Knob Set to 0 Fully anti clockwise click OFF Gas Water Connections Turned ON Main Supply Voltage is between 196Vac 253Vac ...

Page 33: ...ng CON0083A Turn OFF Mains Supply to Heating System on RSL models check that link plug is fitted there is continuity Replace if defective On CFL models check wiring to T T B Thermostat check T T B thermostat continuity replace if defective ...

Page 34: ...Publication No 5102977 34 Fault Finding ...

Page 35: ...Publication No 5102977 35 Fault Finding ...

Page 36: ...Publication No 5102977 36 7 Short List Of Spare Parts Short List Spare Parts Fig 31 50 100 Models 40 Model CON0060D ...

Page 37: ... 380 Potentiometer Wiring Harness Assy 1 840072 12 E02 313 Fan Gasket 1 242045 13 E03 826 Fan Assy c w Gasket CFL RSL40 70 1 242083 E03 827 Fan Assy c w Gasket CFL RSL80 100 1 242084 14 E02 348 Injector 2 9 CFL RSL40 1 411041 173 139 Injector 3 2 CFL RSL50 1 411028 173 136 Injector 3 7 CFL RSL60 1 411024 173 137 Injector 3 9 CFL RSL70 1 411025 E02 234 Injector 4 3 CFL RSL80 1 5105584 E02 349 Injec...

Page 38: ...sion Kit Sales Code ULT2EXTN Max 3 Kit A Extension Air Tube Outer B Extension Flue Tube Inner C Self Tapping Screws 6 off Flat Roof Flashing Kit Sales Code PUMAKITK 90 In Line Bend Kit S Code PUMAKITB A 90 or 135 In Line Elbow B Product Tube O Ring 2 off C Air Tube Clamp Including Nuts Screws D Air Tube Seal 2 off D Fixing Bracket E Woodscrews 2 off F Wall Plugs 2 off A E D F B Concentric Vertical...

Page 39: ...Publication No 5102977 39 Flue Kits Optional Extras Fig 33 Installation instructions included as necessary with each kit CON0095A ...

Page 40: ... to make changes and improve mentsinourproductswhichmayaffecttheaccuracyoftheinformation contained in this leaflet All goods are sold subject to our standard ConditionsofSalewhichareavailableonrequest Toaidcontinuousimprovementandstafftraining callstothis linemaybemonitoredorrecorded General Enquiries Tel Technical Tel Service Tel Fax Literature Request Tel Publication No 5102977 Iss 03 01 2002 ...

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