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221966B

FUSE
TYPE F1 & F2
(F1A)

AIR PRESSURE SWITCH CONNECTIONS

SPARK
ELECTRODE

WATER PRESSURE
SWITCH

O/H CUTOFF

CONTROL

STAT

FAN

AIR
PRESSURE
SWITCH

PILOT
SOLENOID

MAIN
SOLENOID

(N/O)

(C)

(N/C)

N/C

KEY

bk BLACK
br BROWN
b BLUE
p PURPLE
g GREY

or ORANGE
w WHITE
r RED
y YELLOW

MAIN TERMINAL STRIP CONNECTIONS

CONTROL THERMOSTAT CONNECTIONS

PRINTED CIRCUIT BOARD CONNECTIONS

FULLY PUMPED OPEN VENTED
OR SEALED WATER SYSTEM

PUMP

RED

LINK

Remove red link between 9 and SL when

fitting a time control etc (if no switch is fitted,
link will make the circulation pump run constantly)

LInk fitted to bridge out water pressure switch

for open vented system.

LINK

Diagram 11.4

11 Fault Finding

Diagram 11.3

Pump overrun Operation for Fully

Pumped System Only

YES

Faulty PCB. Replace

Does pump stop after several minutes ?

YES

Does the pump run when SL is applied ?

Does pump continue to run after SL is interrupted ?

System satisfactory.

YES

The PCB has a 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.

FOR FULLY PUMPED OPEN VENTED
OR SEALED WATER SYSTEMS ONLY

Содержание Ultimate 100FF

Страница 1: ...number 01773 828100 Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of Guarantee Registration 100FF 120FF Fanned Flue Boiler This is a Cat I2H Appliance BS 6332 BS 5258 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 inst...

Страница 2: ...release of fibres from these RCF articles is kept to a minimum during installation and servicing we recommend that you use a HEPA filtered vacuum to remove any dust accumulated in and around the boiler before and after working on the boiler When replacing these articles we recommend that the replaced items are not broken up but are sealed within heavy duty polythene bags clearly labelled as RCF wa...

Страница 3: ... Installation and Use Regulations In your interest and that of gas safety it is the law that ALL gas appliances are installed by a competent person in accordance with the above regulations Gas Leak or Fault If a gas leak or fault exists or is suspected the boiler must be turned off including the electrical supply and must not be used until the fault has been put right Advice help should be obtaine...

Страница 4: ... Compartment or Cupboard If the boiler is installed in a compartment or cupboard do not obstruct any ventilation openings Do not use the compartment or cupboard for storage Cleaning WARNING This appliance contains metal parts components and care should be taken when handling and cleaning with particular regard to edges Clean the casing occasionally by wiping it over with a damp cloth or dry polish...

Страница 5: ...gnition system switches off and the main burner lights The flames can be seen through the viewing window see diagram 1 The main burner will remain alight until switched off by the control thermostat or any remote control If the boiler is switched OFF by hand wait at least 30 seconds before switching on again When the boiler switches off both the pilot and main burner go out The automatic lighting ...

Страница 6: ...1 Statutory Requirements The installation of the boiler must be carried out by a competent person in accordance with the relevant requirements of the current issue of Manufacturer s instructions supplied TheGasSafety InstallationandUse Regulations TheBuilding Regulations The Building Standards Scotland Regulations applicable in Scotland Local Water Company Byelaws The HealthandSafetyatWorkAct Cont...

Страница 7: ...148 29 24 99 760 26 38 90 000 9 2 3 7 14 4 5 8 11 6 4 7 2 8 100 3 5 123 3 1 111 205727 4 7mm TABLE 2 100FF RANGE RATING NOMINAL HEAT INPUT NETT Min Max Med NOMINAL HEAT OUTPUT APPROX GAS RATE BURNER INJECTOR MARKING kW Btu h kW Btu h m3 h ft3 h BURNER INJECTOR SIZE TABLE 2 120FF RANGE RATING NOMINAL HEAT INPUT NETT Min Max 36 52 124 608 32 24 110 000 3 9 137 Medium NOMINAL HEAT OUTPUT APPROX GAS R...

Страница 8: ...iler is room sealed and does not require the room or space containing it to have permanent airvents 1 14 Boilers in a Compartment Where the installation of the boiler will be in an unusual position special requirements are needed the current issue of BS6798 gives detailed guidance on these requirements A compartment used to enclose the boiler must be designed and constructed specifically for this ...

Страница 9: ...ould be fitted immediately beneath the guttering or eaves 2 2 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and be central over the terminal A suitable guard reference Type K3 can be ...

Страница 10: ...ventfromtheboilermustrisecontinuously to over the feed and expansion cistern 3 5 Domestic Hot Water System General Thedomestichotwaterservicemustbeinaccordance with the current issue of BS5546 refer also to the current issue of BS6700 3 6 Indirect Cylinder For all systems supplying domestic hot water the cylinder must be indirect It is recommended that the indirect cylinder be fitted with some for...

Страница 11: ...given in Data Table 1 3 12 Pressure Gauge A pressure gauge with a set pointer and covering at least the range of 0 to 4bar 0 to 60lb in2 shall be permanently fitted to the system in a position where it can be seen when filling the system Diagram 3 2 6349 FEED AND EXPANSION CISTERN 22mm VENT MIN 15mm MINIMUM COLD FEED OPEN VENTED FULLY PUMPED WATER SYSTEM RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD ...

Страница 12: ...st from the system A make up vessel mounted above the highest point of the system and connected through a non return valve to the system on the return side of either the hot water cylinder or heating system see diagram 3 4 Alternativelyprovisionformakeupcanbemadebyafillingloop 3 LITRES 0 66 gals MAKE UP BOTTLE if required NON RETURN VALVE AUTO AIR VENT FLOW DRAIN COCK BOILER SAFETY VALVE Make up a...

Страница 13: ... If there is insufficient clearance the flue can be installed from outside Diagram 4 3 6854 Diagram 4 1 4792 CARTON Standard Flue terminal illustrated MOUNTING BRACKET INSTRUCTIONS LOOSE ITEMS PACK BOILER WALL TEMPLATE S SIDE FLUE LENGTHS Distance S External wall face to boiler case STD 81mm to 346mm 1M 81mm to 830mm 2M 81mm to 1830mm 3M 81mm to 2830mm 100FF ONLY Diagram 4 2 4275 Standard Flue ter...

Страница 14: ...mensional alignment with the flue hole Mark the boiler fixing points and mounting bracket position see diagram 4 5 Note the mounting bracket has additional holes to allow for further fixings should site conditions require it Drill holes and plug to suit No 12x2in woodscrews fit the screws allowing sufficient clearance about 5mm to accept the swing brackets see diagram 4 5 Secure the mounting brack...

Страница 15: ... the air duct terminal assembly and the flue duct at the lengths shown in diagram 4 7 and 4 9 then cut to length cutting square and removing any burrs Note do not cut the flue duct at the pre drilled end 4 10 Flue Assembly Locate the flue duct drilled end onto the flue elbow and secure with the screws supplied in the loose items pack see diagram 4 10 Locate the flue duct elbow into the air duct te...

Страница 16: ...HE FLUE TERMINAL RESTRICTOR MUST BE POSITIONED AS SHOWN SECURING SCREW 2 FLUE ELBOW FLUE DUCT SEALING TAPE AIR DUCT TERMINAL FLUE ELBOW DUCT STANDARD FLUE TERMINAL 3mm DRILL 4284 Diagram 4 11 WALL THICKNESS UP TO 300mm Q FOAM SEAL WALL THICKNESS OVER 300mm 20mm FOAM SEAL Q Q MINUS 55mm 6859 4 Flue and Appliance Preparation ...

Страница 17: ...er into position hooking over the mounting bracket Swing the brackets over the two screws at the top Hold the swing bracket s in place whilst tightening the screw s on to it see diagram 5 2 Remove the blue and red electrical connections from the fan see diagram 5 3 Diagram 5 1 Diagram 5 2 CONTROLS COVER FRONT COVER SHAKEPROOF WASHER NUT WING NUT 5mm Pipe omitted for clarity 4285 4286 MOUNTING BRAC...

Страница 18: ...e injury to person damage to property or any electrical installation 5 5 Gas Connection Make the gas connection to the Rc 1 2 in gas service cock see diagram 5 5 Check for leaks using a suitable leak detection fluid Diagram 5 5 Diagram 5 3 CLEAR RED FLUE HOOD SECURING SCREW 4 FAN SECURING SCREWS FAN ASSEMBLY AIR PRESSURE SENSING PIPES CLEAR ELECTRICAL CONNECTIONS Diagram 5 4 FLUE HOOD SECURING SCR...

Страница 19: ...int screws see diagram 6 2 Make sure of the correct fitting of the flue to the boiler Pull the flue duct forwards and engage onto the flue elbow Push the air duct back into the wall to the dimension shown in diagram 6 3 Important the flue duct will become disengaged should the dimension be any greater than shown Hold the flue duct onto the flue elbow then secure the flue duct to the flue elbow see...

Страница 20: ...ted NOTE Open Vented Water Systems ONLY Bridge terminals K1 and K2 7 3 Pump Connection The pump must be connected directly to the control box as shown in diagram 7 2 threading the cable through the cable clamp in the side of the control box 7 4 External Controls Any external controls must only be wired to interrupt the red link between terminals SL and 9 Make sure that the supply cable and all ext...

Страница 21: ... by reference to diagram 8 1 Check that the boiler is isolated from the electrical supply Make sure that the control thermostat is turned to O the Off position Turn boiler gas service cock On Test the pilot supply tube and its connection for gas soundness as follows Disconnect the ignition lead from the PCB see diagram 7 2 Remove the combustion chamber front see diagram 8 2 WARNING The fan operate...

Страница 22: ...cock Off see diagram 8 1 After a short period the main burner and pilot will go out 2 The correct working of the flame supervision device is shown by neon 4 going out within 10 seconds and the ignition starting up Neons 1 2 and 3 should stay alight 3 If the above does not happen refer to fault finding Section 11 1 4 To carry on turn the gas service cock On see diagram 8 1 When the boiler switches ...

Страница 23: ...st be fired with the bypass fully closed on full service that is central heating and domestic hot water Adjust the pump to the system design setting then balance the system Having achieved a satisfactory condition operate the boiler with the bypass fully closed on minimum load normally this will be central heating only with one radiator in the main living area operating The bypass valve should be ...

Страница 24: ...son Before servicing turn off the gas and isolate the electrical supply to the boiler After completing a service always test for gas soundness and carry out functional check on controls Unless stated otherwise all parts are replaced in the reverse order to removal 10 1 Access Refer to diagram 8 6 and slide controls cover forward and off Remove the outer case see diagram 8 5 Note As an aid to servi...

Страница 25: ...flue bend systems using corrugated bends see Flue Kit Installations has been fitted then the TOP FLUE BAFFLES will have been REMOVED Note When replacing the bottom three baffles the two half and one whole baffle make sure that they are positioned with the mark 100 to front of appliance as shown in diagram 10 3 120 FF ONLY Remove the baffles see diagram 10 4 Note When replacing the bottom baffle ma...

Страница 26: ...rk gap is as shown in diagram 8 3 10 5 Operational Checks After completing a service and before fitting the case check condition of the case seal and renew if necessary Examine the flue hood and terminal to make sure they are clean and clear of obstructions Light the boiler and carry out the functional checks as described in Section 8 Diagram 10 5 Diagram 10 6 PILOT BURNER SPRING CLIP ELECTRODE PI...

Страница 27: ...ffoperatesatanyothertimepresstheresetbuttonand the burner should relight If the fault persists refer to the fault finding chart Diagram11 1 Neon Indicators An Aid to Fault Finding THE NEON INDICATORS ARE AN AID TO FAULT FINDING ONLY FAILURE OF ANY OF THE NEON INDICATORS DOES NOT WARRANT THE REPLACEMENT OF AN OTHERWISE SATISFACTORY PRINTED CIRCUIT BOARD PCB Is neon 1 lit Fault with mains supply or ...

Страница 28: ...ck ALL cables connections and the printed circuit board fuse Check the air tubes to the air pressure switch Switch on the electrical supply and check for correct polarity Turn the control thermostat to its maximum setting Also check fuses Check overheat reset If satisfactory replace overheat device Is neon 2 lit NO Is there 230V between K1 and N YES YES Check 0 2 Bar of water pressure is available...

Страница 29: ...control etc if no switch is fitted link will make the circulation pump run constantly LInk fitted to bridge out water pressure switch for open vented system F1 F2 or or or p LINK Diagram 11 4 11 Fault Finding Diagram 11 3 Pump overrun Operation for Fully Pumped System Only YES NO Faulty PCB Replace Does pump stop after several minutes YES Does the pump run when SL is applied Does pump continue to ...

Страница 30: ...TRODE SEQUENCE BOARD CHASSIS EARTH g y p b br CHASSIS EARTH g y p or b w y y CONTROL THERMOSTAT OVERHEAT CUTOFF br L N E N L E b b br g y br C NC g y w 230 50Hz PERMANENT MAINS SUPPLY FUSED AT 3 AMP CIRCULATION PUMP w FUSES F1 F2 F1A K2 K1 PN SL P 9 N L NOTE Bridge out Water Pressure Switch between K1 K2 if using open vented system 3 PLUGS See Note g y NC bk NO C p g FULLY PUMPED OPEN VENTED OR SE...

Страница 31: ...e and the plastic retainingclipthenremoveitfromthesplitgrommet Releasethe capillary from its clips Remove the thermostat complete from the boiler Reassemblynote Whenrefittingthethermostatmakesurethat the thermostat phial is covered with heat sink compound then fully inserted into the phial pocket and that the capillary is within the gland seal see diagram 12 2 Remake the electrical connections The...

Страница 32: ...Support the multifunctional control remove the four extended screws from the flanged connections at the left and right hand side Remove and discard the original O rings from the flanged connection and fit the new O rings supplied into recess before fitting the replacement multifunctional control After assembly test for gas soundness and purge in accordance with the current issue of BS6891 12 8 Sol...

Страница 33: ...ram 12 5 Ensure no air bubbles are trapped underneath the foil 12 13 Air Pressure Switch diagram 12 6 Release the control box as Section 7 1 Remove the pressure tubes and the electrical connections from the PCB release the screws and remove the switch When fitting the replacement make sure that the plastic tubes and electrical connections are made as shown in diagram 11 5 and 12 6 Diagram 12 3 SOL...

Страница 34: ...E SWITCH ELECTRICAL CONNECTIONS CONTROL BOX Diagram 12 7 9077 WATER PRESSURE SWITCH ELECTRICAL CONNECTIONS PURPLE GREY 4304 12 14 Fan diagram 5 3 Remove the electrical connections and disconnect the air pressure tubes Remove the fan assembly securing screws Make sure that the earth connection is remade onto the new fan assembly The polarity of the other connections is not important 12 Replacement ...

Страница 35: ...lectrode and lead 100FF 313 998 7 202629 Spark electrode and lead 120FF 278 238 8 K3580 Clip electrode 390 983 9 800850 Thermostat control 10 202232 Air pressure switch 100FF 278 239 10 202201 Air pressure switch 120FF 313 992 11 800275 Control knob 313 609 12 800656 Water pressure switch 13 204212 O ring 281 343 14 202015 Fuse 334 750 15 900847 Control board PCB 16 800272 Overheat safety cutoff 3...

Страница 36: ...36 221966B Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions ...

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