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221785B

Diagram 8.8

FLUE BLOCKAGE
SAFETY DEVICE

ELECTRICAL
CONNECTIONS

5315

SECURING
SCREW (2)

PHIAL

SAFETY
DEVICE

LOCKNUT

Disconnect the pilot supply tube by unscrewing the tubing nut.
Remove the pilot burner by unscrewing the fixing at the left hand
side.

Reassembly Note:  When refitting check that the spark gap is
correct and ensure that the thermocouple tip will be enveloped
as shown in diagram 6.3.

8.11 Thermostat

Gain access as Section 8.1.  Refer to diagram 5.2, 8.5, 8.6 and
8.7.

Remove and temporarily support the electrical control box as
described in Section 5.1.

Remove the control knob.  Remove the two electrical connections
from the thermostat body.

Release the thermostat body by unscrewing the two screws in
the front of the control box.

Remove the split pin.  Withdraw the retaining angle and
thermostat phial from its pocket.

Remove the thermostat from the boiler.

Re-assembly note:  When fitting the thermostat, make sure that
the thermostat is fully inserted into the phial pocket and then
insert the retaining angle.   Replace the split pin.

Remake electrical connections.

Make sure that the capillary is positioned as before so that it
passes through the cut out in the control box, see diagram 8.5,
and that any excess being coiled up tidily at the rear of the
control box.  There must be no kinks or sharp bends in the
capillary.

8.12 Peizo Unit

Gain access as Section 8.1.  Refer to diagram 8.7.

Remove the electrical control box, refer to Section 5.1.

Disconnect the ignition lead at the piezo unit.

Note: To ease the removal of the piezo unit it is advisable to
temporarily remove the boiler thermostat from the control box,
refer to Section 8.11.

Depress the retaining tabs and remove the Piezo unit.

8.13 Ignition Lead

Gain access as Sections 8.1 and 5.1.

Disconnect the lead at both ends and remove.

Re-assembly note:  When replacing make sure the black end of
the lead is attached to the piezo unit.

8 Servicing and Replacement of Parts

THERMOSTAT
CAPILLARY

PHIAL
RETAINING
ANGLE

PHIAL
POCKET

RETAINING
SPLIT PIN

SECURING THE
THERMOSTAT PHIAL

Diagram 8.6

2171

8.14 Flue Blockage Safety Device

Gain access as Section 8.1.

Remove the flue cleaning door, refer diagram 4.6.

Unscrew the two securing nuts and withdraw the phial assembly,
see diagram 8.8.

Remove capillary from clips.

Remove the electrical connections from the safety device.

Remove the locknut securing the safety device to the bracket
and withdraw the safety device.

PIEZO UNIT

Diagram 8.7

8039

PIEZO
UNIT

CONTROL
BOX

CAPILLARY

Содержание Ultimate 40CF

Страница 1: ...ce of mind plus valuable protection against breakdown by covering the cost of Guarantee Registration Open 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 The instructions consist of three parts User Installation and Servicing Instructions which includes the Guarantee...

Страница 2: ...uels 2 Directive 73 23 EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER Under Section 6 of The Health and Safety at Work Act 1974 we are ...

Страница 3: ...n on the control tray Please be advised that the Benchmark logbook should be completed by the installation engineer on completion of commissioning and servicing All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your boiler Logbook You can check your installer is CORGI registered by calling CORGI direct on 01256 372300 Boiler Clearances ...

Страница 4: ...RMOSTAT CONTROL KNOB C GAS SERVICE COCK SHOWN IN OFF POSITION D CONTROL BUTTON GAS E VIEWING WINDOW F FLUE BLOCKAGE SAFETY DEVICE RESET BUTTON E F B A DATA LABEL Turn thermostat knob B faulty anticlockwise to the O Off position Push in control knob D keep pushed in push and release piezo button A until the pilot lights Look through window E After the pilot burner lights keep the button pushed in f...

Страница 5: ...Range Rating The boiler is range rated and may be adjusted to suit the individual system requirements The respective Table 1 gives the ratings and settings A B C D E F H K L M N R S 764 265 168 213 149 24 5 39 115 741 417 640 345 23 MODEL Diagram 1 1 GENERAL DIMENSIONS all dimensions in mm 40CF 0020M B D C H F A R L N GAS CONNECTION RC1 2 1 2 in BSPT WATER CONNECTION RC1 1in BSPT M K E S C L C L F...

Страница 6: ...boiler must be mounted on a flat wall which is sufficiently robust to take its weight 1 12 Boiler Clearances Refer to diagram 4 4 The boiler must be positioned so that at least the minimum operational and servicing clearances are provided Additional clearances may be required for installation If fixtures are positioned next to the boiler they should be made removable for access to pipework Suffici...

Страница 7: ...a cavity wall must be ducted If there are other fuel burning appliances present allowance must be made for their combustion requirements The free area for the boiler is 40CF 38cm2 5in2 Refer also to the current issue of BS5440 Part 2 2 3 Products of Combustion Test the boiler for clearance of flue products at the draught diverter as detailed in the current issue of BS5440 Part 1 2 4 Extract Fans I...

Страница 8: ...o C 20o F between flow and return with the boiler thermostat set at MAX which is about 82o C 180o F The resistance through the boiler can be found from diagram 3 3 4 Installation 4 1 Unpacking Unpack and check that the contents listed below are present and undamaged Boiler combustion chamber shield side panels x 2 burner flueway baffle loose items pack with check list With the boiler still in the ...

Страница 9: ...e so that the tags on the boiler body locate on the cross member of the wallframe see diagram 4 5 Fasten the boiler to the wallframe using the screws previously removed Remove the flue cleaning door see diagram 4 6 Remove the split pin Withdraw the retaining angle and thermostat phial from its pocket Fit the flueway baffle making sure that it is seated down correctly onto the casing as shown in di...

Страница 10: ...fittings Fill vent and cold flush the system as recommended in the current issue of BS6798 Visually check for and put right any water leaks 4 5 Gas Connection Make the gas connection to the flanged Rc1 2 gas service cock 4 6 Flue Installthefluepipeworkandsealtothefluesocketinaccordance with normal practice 5 Electrical Connection 5 2 Cable Connection Thread the mains cable through the clamp at the...

Страница 11: ...ntrol 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 pushe...

Страница 12: ...e cover removed for clarity A ELECTRICAL CONTROL BOX B THERMOSTAT CONTROL KNOB C GAS SERVICE COCK SHOWN IN OFF POSITION D MULTI FUNCTIONAL CONTROL E PRESSURE TEST NIPPLE F GAS BURNER TEST NIPPLE G PIEZO UNIT BUTTON H THERMOCOUPLE PIPE K CONTROL BUTTON GAS M CASE SECURING SCREW N PILOT BURNER PRESSURE SCREW P FLUE BLOCKAGE SAFETY DEVICE RESET BUTTON 8052 E M G B A H P C K D N F Check the operation ...

Страница 13: ...ue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance It is the Law that any servicing must be carried out by a competent person Advise that the boiler is fitted with a safety device and refer to the Instructions for Use Advisetheuseroftheprecautionsnecessarytopreventdamage to the system and ...

Страница 14: ...ay baffle ensure they are fitted as shown in diagram 4 6 8 4 Multifunctional Control Servicing Replacement Gain access as Section 8 1 Refer to diagram 6 4 and 8 1 Remove multifunctional control cover securing screw Disconnect the electrical leads thermocouple and pilot supply tube at the multifunctional control Remove the flue blockage safety device securing locknut and release from bracket taking...

Страница 15: ...mocouple spring clip and remove the thermocouple Re assembly note When refitting do not tighten the thermocouple nut more than a quarter turn beyond finger tight 8 10 Pilot Burner Gain access as Section 8 1 Refer to diagram 6 3 and 8 4 Remove the main burner as described in Section 8 2 Remove electrode as described in Section 8 7 Disengage the thermocouple spring clip and carefully ease the thermo...

Страница 16: ...led up tidily at the rear of the control box There must be no kinks or sharp bends in the capillary 8 12 Peizo Unit Gain access as Section 8 1 Refer to diagram 8 7 Remove the electrical control box refer to Section 5 1 Disconnect the ignition lead at the piezo unit Note To ease the removal of the piezo unit it is advisable to temporarily remove the boiler thermostat from the control box refer to S...

Страница 17: ...ple Check aeration If necessary Clean pilot rectify blockage in pilot injector or replace Check thermocouple circuit using Thermocouple fault finding diagram On pressing piezo unit button is there a spark across electrode gap Pull ignition lead off electrode Hold end of lead close to pilot burner and operate piezo unit Is there a spark across gap Pull ignition lead off piezo unit Using blade of a ...

Страница 18: ...the flue blockage safety device Is there continuity YES NO NO PERMANENT LIVE 230V 50Hz 3A FUSE THERMOSTAT L RED C NC BROWN MULTI FUNCTIONAL CONTROL SOLENOID BLUE N 3 4 Diagram 9 3 FUNCTIONAL FLOW WIRING 2327 B Diagram 9 2 THERMOCOUPLE FAULT FINDING 9 1 Pilot Refer to chart 9 1 9 2 Thermocouple Refer to chart and diagram 9 2 9 3 Electrical Refer to diagram 9 3 and 9 4 The preliminary electrical sys...

Страница 19: ...s available and the pilot is lit Isolate electrical supply to the control box Remove the control box cover and check all cables Turn boiler thermostat to Max Is there continuity between C and NC Turn boiler thermostat to O Is there open circuit between C and NC Faulty thermostat Replace Restore electrical supply with pilot burner lit and boiler thermostat set between MIN and MAX does the main burn...

Страница 20: ...Injector 355 274 4 K2674 Thermocouple 390 894 5 K3580 Clip thermocouple 390 983 6 203416 Pilot burner 381 793 7 900500 Spark electrode 381 733 8 WW4617 Ignition lead 312 997 9 202519 Thermostat 381 798 10 204687 Control knob 11 202713 Piezo unit 12 801236 Mica window and foil gasket 13 203350 Solenoid 14 800755 Safety device 278 469 Because of our constant endeavour for improvement details may var...

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