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7

221785B

The flue must be installed in accordance with the
recommendations in the current issue of BS5440 Part 1.

The flue should be kept as short as possible.

Horizontal or very shallow runs should be avoided.

Give maximum possible vertical rise from the boiler, minimum
600mm (24in) before any bend.

The use of 45

o

 bends is recommended.

A slip-on loose collar must be provided for flue removal.

End with a certificated terminal, above ridge height, if possible,
if not, at least above the eaves of a pitched roof.

A previously used chimney must be swept and any register
plate or damper or the like must be removed or locked in the
open position and the chimney made good.

2.2 Boilers in a Compartment

Where the installation of the boiler will be in an unusual location,
special procedures are necessary.  Refer to the current issue of
BS6798 for guidance.

A compartment used to enclose the boiler must be designed
and constructed specifically for this purpose.

An existing cupboard or compartment modified for the purpose
may be used.  Refer to the current issue of BS6798 for
guidance.

The doorway opening should be of sufficient size to allow for
easy removal of the boiler.

Be provided with permanent ventilation openings as shown in
the respective Table 2.  These figures are for the minimum free
area.

The high and low level openings must communicate with the
same room or space or must both be on the same wall to outside
air.

The compartment door or vent should not communicate with a
private garage, bedroom, bed sitting room or a room containing
a bath or shower.

2.2A Boilers in a Room or Space

A purpose designed ventilation opening must be provided on an
outside wall of the building, this opening may be either, directly
into the room or space containing the boiler, or into an adjacent
room or space which has an internal permanent air vent of the
same size to the room containing the boiler.

Do not ventilate through a kitchen, private garage, bathroom or
toilet.

Vents through 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 - 38cm

2

 (5in

2

)

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

If an extract fan is fitted there is a possibility that if adequate air
is not provided spillage of the flue products could occur.  If vents
are fitted in accordance with the above recommendations this
should not occur.

Where such an installation is found a spillage test must be
carried out as detailed in the current issue of BS5440 Part 1 and
any necessary action taken.

2.5 Timber Frame Buildings

If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
document IGE/UP/7/1998.  If in doubt seek advice from the local
gas undertaking or Hepworth Heating Ltd.

Frost Protection

If the position of the boiler is such that it may be vulnerable to
freezing it should be protected as specified in the current issue
of BS5422.  It is also recommended that a frost protection
thermostat be fitted.

3.1 Cylinders

For all systems supplying domestic hot water the cylinder must
be indirect.  It is recommended that the cylinder be fitted with
some form of temperature control.

3.2 Gravity Domestic Hot Water with Pumped
Heating

It is important that the flow and return connections are in the
same relative positions as shown in diagram 3.1.

The domestic flow and return must both be on one side of the
heat exchanger.  The heating flow and return are taken from the
other.

2 Flue and Ventilation

3 Water Systems

27 metres
Max.

28mm

PUMP

MIDWAY BETWEEN
BOILER TAPPINGS

HEATING
SYSTEM

INDIRECT
CYLINDER
(Shown with
recommended
thermostat and valve).

22mm VENT

15mm COLD FEED

REFER TO BS 5546

Diagram 3.1

GRAVITY HOT WATER
SYSTEM (DIAGRAMMATIC)

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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