Potterton Kingfisher Mf Installation & Service Instructions Manual Download

Page: 37 / 40

Publication No. 5102977

Short List Spare Parts

Item No.

G.C. No.

Description

Qty.

Part No.

E02-325

Thermistor

404524

173-130

Overheat Thermostat

404517

E02-367

Main Wiring Harness

242110

E78-236

Gas Valve Assembly CFL/RSL40 - 100

5102729

379-672

Pilot Burner - Honeywell

402559

114-963

'O' Ring

401656

E02-372

Electrode - Honeywell

402561

E02-365

Main PCB

840073

E02-379

User Control Board

650451

E78-250

Pressure Switch Assembly - CFL50 - 100, RSL40, 60, 90, 100

5105796

E78-367

Pressure Switch Assembly - CFL40, RSL50

5105795

E02-376

Pressure Switch Assembly - RSL70

642482

E78-369

Pressure Switch Assembly - RSL80

5105798

E02-380

Potentiometer/Wiring Harness Assy

840072

E02-313

Fan Gasket

242045

E03-826

Fan Assy c/w Gasket - CFL/RSL40 - 70

242083

E03-827

Fan Assy c/w Gasket - CFL/RSL80 - 100

242084

E02-348

Injector 2.9 - CFL/RSL40

411041

173-139

Injector 3.2 - CFL/RSL50

411028

173-136

Injector 3.7 - CFL/RSL60

411024

173-137

Injector 3.9 - CFL/RSL70

411025

E02-234

Injector 4.3 - CFL/RSL80

5105584

E02-349

Injector 4.4 - CFL/RSL90

411039

E02-350

Injector 4.7 - CFL/RSL100

411040

405-562

Injector Washer

400984

E82-317

Burner - Aeromatic - CFL/RSL40

5106796

E78-210

Burner - Aeromatic - CFL/RSL50 - 70

5105582

E78-212

Burner - Aeromatic - CFL/RSL80

5105583

E02-347

Burner - Aeromatic - CFL/RSL90 - 100

414821

E78-180

Products Discharge Safety Device - TTB

5102808

CFL40, 50 (Blue sleeve)

E78-181

Products Discharge Safety Device - TTB

5102809

CFL60 - 100 (Yellow sleeve)

Summary of Contents for Kingfisher Mf

Page 1: ...s of Statutory Instrument The Boiler Efficiency Regulations 1993 No 3083 and is deemed to meet the requirements of Directive 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purpose of Regulation 5 certified by Notified Body 0087 Product Production certified by Notified Body 0086 For use with Natural Gas G20 only at 20mbar a...

Page 2: ...nsure safety and efficiency Important Failure to install and commission this appliance to manufacturer s instructions may invalidate the warranty This note does not affect your statutory rights CORGI All CORGI registered installers carry a CORGI identification card and have a registration number Both should be recorded in your boiler Log Book You can check your installer is registered by telephoni...

Page 3: ...Gas Supply Pressure 20 mbar Gas Supply Connection Rc 1 2 1 2 BSP Female Maximum Flow Temperature 82 C Flow Connection 28 mm Copper Return Connections Gravity 28 mm Copper Return Connections Pumped 28 mm Copper Water Content 6 5 litres Appliance Weight Installed Dry 65 0 kg RSL 69 0 kg CFL Electricity Supply 230v 50Hz Fused at 3A Internal Fuse Type 2 AT 2 off Power Consumption 80 Watts excluding pu...

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: ...hly wash hands after installation servicing or changing components f When disposing of any items manufactured from man made mineral fibre care must be exercised g If any irritation of the eyes or severe irritation of the skin is experienced seek medical attention 1 2 Codes of Practice The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules ...

Page 6: ... the flue duct is not closer than 25 mm to combustible 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 clause 4 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institution of Gas Engineers Publication IGE UP 7 Gas In...

Page 7: ...than 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 requi...

Page 8: ...le a 125 mm Dia flue size should be used irrespective of the boiler size 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 In all cases where horizontal or inclined runs occur then the minimum vertical flue length must exceed 1 5 m If an existing chimney is used ensure that it...

Page 9: ... 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 A flue terminal assembly suitable for a wall thickness of 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 A 1m flue extension is available Under ...

Page 10: ...ted within 1 metre of a plastic gutter within 500 mm of a painted eave or a painted gutter an aluminium shield of at least 1 metre long should be fitted to the underside of the gutter or painted surface An air space of 5 mm should be left between shield and gutter IMPORTANT It is absolutely ESSENTIAL to ensure that products of combustion discharging from the terminal cannot re enter the building o...

Page 11: ...flow and two return connections On combined gravity DHW Pumped central heating a Tee will be needed in the flow which must be fitted directly to the connecting pipe provided Fully Pumped Systems The pump must be wired directly to the terminal block See Fig 20 as it will allow the pump to be controlled by the over run device This will ensure that the pump will continue to run after boiler shut down...

Page 12: ...4 2 of the Water Regulations Guide for IE the current edition of I S 813 Domestic Gas Installations 1 0 1 0 V x 0 087 Vessel Charge Pressure bar Initial System Pressure bar Expansion Vessel Volume litres 0 5 1 0 V x 0 11 Table 4 Fig 7 Stop Valve CH Return Temporary Hose Stop Valve Double Check Valve DHW Mains Inlet sup2005a Filling Point Requirements Expansion Vessel A diaphragm type expansion ves...

Page 13: ...Publication No 5102977 13 CON0093B Installation Requirements Fig 9 Fig 8 ...

Page 14: ...put are shown in Table 5 If other controls such as 3 position valves are used in the system the resistance through them quoted in their manufacturers literature must be taken into account The pump may be fitted on either flow or return It must be fitted with two isolating valves which are positioned as close to the pump as possible Closing of any valve must always leave the open vent unobstructed ...

Page 15: ...sure 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 12...

Page 16: ...already assembled 2 See Section 4 9 on page 28 of the Installation Service Instructions remove the products discharge safety device TTB and carefully place on top of the appliance 3 Remove the 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 ...

Page 17: ...els 3 4 m 80 model 2 4 m 90 model 1 4 m 100 model 1 0 m These are for rear or side flue applications 3 Determine dimension X 20 mm See Fig 13 4 Extend telescopic flue to the required length minimum 20 mm overlap 5 Drill through the pilot hole and secure with a self tapping screw 6 Wrap tape around the joint on the outer duct to seal the flue slide drip ring into position to coincide with the air g...

Page 18: ...shown 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 fim 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 For flue lengths less than the minimum tele...

Page 19: ...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 Connect system pipework to the boiler compression fittings should be used Arrange pipework to ensure correct venting of pipes and boiler On gravity systems a tee is required in the flow which must be fitted directly to the connecting pipe supplied...

Page 20: ...ms connect pump to Pump L N E on the terminal block 2 Where no integral programmer is fitted connect the wires as follows Gravity DHW Pumped CH Systems a Fit a link between terminals MAINS SwL and MAINS L b Switched live from external gravity DHW 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 termi...

Page 21: ... slack is available to the cable clamps to allow the control panel to hinge freely Check by opening the control panel If fitting the optional integral programmer go to section 2 6 before performing steps 4 and 5 below 4 Secure the controls assembly to the chassis using the screw previously removed 5 Carry out preliminary electrical system checks i e Earth Continuity Short Circuit Polarity and Resi...

Page 22: ...dness open all windows and doors in the room Extinguish all naked lights cigarettes pipes etc 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: ...ilot flame is established the main burner will ignite and the Green Flame led on the control panel will illuminate Note On initial lighting pilot ignition may be delayed due to the presence of air in the gas supply 9 With the burner running check for gas soundness using leak detection fluid 10 CFL Models Only Carry out a spillage flue pull test as follows Loosen the screw securing the Products Dis...

Page 24: ... controls assembly repeated shutdown by this device should be investigated further and any fault eliminated Other Boiler Controls No further setting or checking is necessary as all boiler mounted controls are designed so that if a fault should occur they will fail safe External Controls Check that any other external controls connected in the system such as clocks or thermostats are correctly set a...

Page 25: ...he flue so an accurate reading can be obtained IMPORTANT Ensure the Products Discharge Safety Device TTB is repositioned correctly after the test and secured to the dimension shown in Fig 28 Notes on Cleaning Boiler Components Heat Exchanger After performing operations 4 1 4 6 4 8 place a sheet of paper under the heat exchanger then using a flat blade tool Part No 907736 scrape the flueway fin sur...

Page 26: ...removal or replacement of any gas carrying component a test for gas soundness must be made and functional check 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 p...

Page 27: ...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 sensor and pu...

Page 28: ... 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 assembl...

Page 29: ... Remove the fluehood 2 screws and withdraw it from the boiler 5 Fluehood On re assembly check the seal on the fluehood and replace if damaged and ensure that the fluehood locates under the bracket at the rear of the chassis 6 Fan On re assembly check the seal on the fan inlet and replace if damaged ensure that the rubber seal around the fan outlet is located correctly into the base of the flue elb...

Page 30: ...Publication No 5102977 30 5 Wiring Diagrams Functional Wiring Diagram Fig 29 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 12 3 13 10 17 11 16 1 8 2 6 4 16 9 14 15 5 7 CON0060D ...

Page 37: ...02 380 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 Inj...

Page 38: ...on Kit Part Number B4286 Max 3 Kit A Extension Air Tube Outer B Extension Flue Tube Inner C Self Tapping Screws 6 off Flat Roof Flashing Kit Part Number 31 19040 90 In Line Bend Kit Part No 31 19034 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 F...

Page 39: ...ach kit CON0095A Internal Fitment Kit Part Number 238012 Programmer Kit Part Number 5106321 Terminal Wall Plate Kit Part Number 242264 Wall Plate Pack Part Number 238013 Terminal Guard Part Number 205792 Flexible Pipe Kit Part Number 242262 Side Infill Panel Kit Part Number 242148 Pump Cover Kit Part Number 242263 ...

Page 40: ... been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request General Enquiries GB Tel 08706 060 780 Technical GB Tel 08706 049 049 Service GB Tel 08706 096 096 Fax 01926 410 006 Literature Reque...

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