Potterton Kingfisher Mf CFL40 - 100 Montage- und Wartungsanleitung

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.

LeavetheseinstructionsandtheBenchmarkLogBookwiththeuserforuseonfuturecalls.

Installation & Service Instructions Kingfisher Mf

RSL40 - 100, CFL40 -100

CON0005A

The code of practice for the installation,

commissioning & servicing of central heating systems

Publication No. 5102977

Flame Lock-out Re-set

Control Panel Serial Number Badge

CON0092B

Data Badge

50 -100

Data Badge

Contents

TechnicalData........................................................3

Introduction..................................................................5

Health&SafetyInformation............................................5

Codesof Practice...........................................................5

1. InstallationRequirements................................6

1.1 GasSupply.......................................................6

1.2 ElectricitySupply..............................................6

1.3 LocationofBoiler..............................................6

1.4 Air Supply - CFL/RSL..................................7/9

1.5 Flue Systems - CFL/RSL.............................8/9

1.6 The System...................................................11

2. Installation...................................................15

2.1 InstalltheBoiler...............................................15

2.2 InstalltheFlue CFL.........................................15

Installthe Flue RSL........................................17

2.3 ConnecttheGas Supply.................................19

2.4 ConnecttheWater Supply..............................19

2.5 ConnectthePowerSupplyCable.....................20

2.6 InstalltheOptionalProgrammer......................21

3. Commissioning............................................22

3.1 CommissiontheBoiler....................................23

3.2 FinalAdjustments..........................................23

3.3 InstructtheUser.............................................24

3.4 AdvisetheUser..............................................24

4. Service&Replacementof Parts......................25

4.1 GeneralAccess.............................................26

4.2 Electronic ControlBoard..................................27

4.3 AirPressureSwitch........................................27

4.4 Temperature Sensor.......................................27

4.5 Overheat Thermostat......................................27

4.6 Burner, Gas Valve, Injector &

Electrode...................................................28

4.7 CombustionChamberInsulation......................29

4.8 Fan&Flue Hood.............................................29

4.9 Products Discharge Safety Device

-TTB(CFLModelsOnly).................................29

5. WiringDiagrams..............................................30

6. FaultFinding....................................................32

7. ShortListof Spares.........................................36

8. FlueKits&OptionalExtras...............................38

Theboilermodel and serial number aregiven

ontheboilerdatalabel which is located on the

heat exchanger cover plate.

The models covered by these instructions 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 Mf RSL 70 - G.C. No. 41 590 38

Kingfisher Mf RSL 80 - G.C. No. 41 590 39

Kingfisher Mf RSL 90 - G.C. No. 41 590 40

Kingfisher Mf RSL 100 - G.C. No. 41 590 41

SAFETY, PERFORMANCE & QUALITY

Kingfisher Mf boilers have been assessed by a

Government appointed Notified Body and shown to

meet the 'Essential Requirements' of the European

Gas Appliance Directive.

The Directive lays down requirements for the safety

and efficiency of the appliance, together with its

design, construction, and use of materials.

It also requires the production process to be covered

by an approved and monitored system of quality

assurance.

Fig. 1

Pottertonisa member of theBenchmarkinitiative and

fullysupportstheaimsoftheprogramme. Benchmark

has been introduced to improve the standards of

installation and commissioning of central heating

systems in the UK and to encourage the regular

servicing of all central heating systems to ensure

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.

Publication No. 5102977 3Technical Data

Technical Data

Heat Input & Efficiency

figures are quoted as gross

Boiler models

40 50 60 70 80 90 100

Maximum Rate

Output kW 11.72 14.65 17.58 20.52 23.45 26.38 29.31

Btu/h 40,000 50,000 60,000 70,000 80,000 90,000 100,000

Input kW 14.47 18.31 22.00 25.60 28.95 32.98 36.76

Btu/h 49,372 62,474 75,064 87,347 98,777 112,528 125,425

Gas rate m³/h 1.38 1.75 2.10 2.44 2.76 3.14 3.50

ft³/h 48.73 61.65 73.98 86.31 97.42 110.97 123.75

Efficiency % 81.0 80.0 80.0 80.0 81.0 80.0 79.7

BurnerPressure mbar 13.5 14.8 11.9 12.1 11.3 13.1 13.0

in wg 5.42 5.92 4.76 4.54 4.54 5.24 5.20

Injector Size mm 2.9 3.2 3.7 3.9 4.3 4.4 4.7

MaximumWorkingHead 30.5 m (3 bar)

MinimumWorkingHead 300 mm

Minimum Circulating Head - Gravity 1.2 m

Gas Supply Pressure 20mbar

Gas Supply Connection Rc. ½ (½ in BSP Female)

MaximumFlowTemperature 82 °C

FlowConnection 28 mm Copper

Return Connections - Gravity 28 mm Copper

Return Connections - 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)

Classifications CAT I 2H

2H G20 20 mbar

B22, C12, C32 (40 - 70 models)

B22, C12 (80 - 100 models)

IP20

NOx Class 1 - CFL90, 100 & RSL60, 70, 80, 90, 100 models

NOx Class 2 - CFL40, 60, 70, 80 & RSL40, 50 models

NOx Class 3 - CFL50 model

SEDBUK Declaration for Kingfisher

Model Seasonal Efficiency

(SEDBUK) (%)

RSL CFL

40 78.5 78.4

50 78.5 78.5

60 78.5 78.0

70 78.1 78.0

80 78.2 78.3

90 78.1 78.0

100 78.0 78.0

This value is used in the UK

Government's Standard Assessment

Procedure (SAP) for energy rating of

dwellings. The test data from which it

has been calculated have been certified

by 0086.

Publication No. 5102977

4 Technical 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

Publication No. 5102977 5

Introduction

The Gas Safety (Installation and Use) Regulations 1998.

This appliance must be installed and serviced by a

competent person, in accordance with the above

regulations.

IntheUK'Corgi'Registered Installers (including the regions

of British Gas Services) undertake to work to a safe and

satisfactory standard.

Failure to install appliances correctly could lead to

prosecution.

It is in your own interest, and that of safety, to ensure that

the regulations are complied with.

Kingfisher Mf boilers are fully automatically controlled,

floor standing, fan powered, balanced or conventional

flued appliances using a cast iron heat exchanger and are

availablein outputs rangingfrom 11.72 -29.31 kW (40,000

- 100,000 Btu/h)

The boilers are designed for use on fully pumped open

vented or sealed water systems with an indirect hot water

cylinder or open vented gravity systems. THEY MUST

NOT BE CONNECTED TO A DIRECT CYLINDER.

The boilers are for use on Natural Gas (G20) only.

Samples of the Kingfisher Mf gas boilers have been

examined by Advantica Technologies Limited, a United

Kingdom Notified Body. The range is certified to comply

with the essential requirements of the Gas Appliance

Directive 90/396/EEC, the Low Voltage Directive 72/23/

EEC and shows compliance with the Electro Magnetic

Compatibility Directive 89/336/EEC, the Boiler Efficiency

Directive 92/42/EEC and are therefore permitted to carry

the CE Mark.

Delivery & Kits Available

RSL Model is delivered in two packages (1) the boiler with

fittings and (2) the flue assembly.

CFL Model is delivered in one package.

Various flue kits and other options for the Kingfisher Mf

range of boilers are shown on Pages 38 & 39.

Health and Safety Information for the Installer

and Service Engineer

Under 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.

Known Hazards - Some people can suffer reddening

and itching of the skin. Fibre entry into the eye will

cause foreign body irritation which can cause severe

irritation to people wearing contact lenses. Irritation to

respiratory tract.

Precautions - Dust goggles will protect eyes. People

with a history of skin complaints may be particularly

susceptible to irritation. High dust levels are only likely

to arise following harsh abrasion. In general, normal

handling and use will not present high risk, follow good

hygiene practices, wash hands before, touching eyes,

consuming food, drinking or using the toilet.

First Aid - Medical attention must be sought following

eye contact or prolonged reddening of the skin.

Codes of Practice

The boiler must be installed in accordance with: The Gas

Safety (Installation and Use) Regulations 1998 and the

current issue of:-

The Building Regulations, Building Standards (Scotland)

Regulations, Local Building Regulations, Model and local

Water Undertaking Bye-laws, IEE Wiring Regulations and

Health & Safety Document No. 635 "The Electricity at

WorkRegulations1989".

For Irelandinstall in accordance withI.S. 813 "Installation

of Gas Appliances".

IMPORTANT

This appliance has been certified for safety. It is therefore important that no external control device (e.g. flue

dampers, economisers, etc.) be directly connected to the appliance unless covered by these Installation &

Service Instructions or otherwise recommended in writing. Any direct connection of a control device not

approved by Potterton could invalidate the CE Certification and normal appliance warranty.

Publication No. 5102977

6 Installation Requirements

1. Installation Requirements

1.1 Gas Supply

The meter and supply pipes must be capable of delivering

thisquantityofgasinadditiontothedemandfromanyother

appliances in the house and must be governed at the

meter.

On 90 & 100 models, due to the gas flow rate required,

22mm gas supply pipe should be used up to the inlet

connection of the gas cock on the boiler.

Thecompleteinstallationmustbe tested for gas soundness

and purged as described in BS6891.

1.2 Electricity Supply

230V ~ 50Hz via a fused double pole switch with a contact

separation of at least 3 mm in both poles adjacent to the

boiler. Power consumption is approximately 80W. There

must be only one common isolator for the boiler and its

control system and it must provide complete electrical

isolation. A plug (if fitted) must be accessible to the user

after installation of the appliance.

Fuse the supply at 3 A. The minimum requirement for the

power supply cable is that it should be a PVC sheathed

cord at least 0.75 mm² (24 x 0.2 mm) (code designation

HO5 VV-F or HO5 VVH2-F) as specified in table 16 of

BS6500:1984.

All wiring external to the boiler shall comply with the latest

IEE Wiring Regulations, and any local regulations which

apply.

WARNING: THIS APPLIANCE MUST BE EARTHED.

In the event of an electrical fault after installation of the

boiler, preliminary electrical systems checks must be

carried out i.e. Earth Continuity, Short Circuit, Polarity and

Resistance to Earth.

1.3 Location of Boiler

Theboileris not suitable for external installation.Theboiler

must stand firm and level. No special floor protection is

needed,butfinisheswhichsoftenwhenwarme.g.linoleum

and plastic floor tiles should be removed or may be

protected by an insulating sheet at least 10mm thick.

The boiler must be installed so that the flue terminal is

exposed to the external air. It is important that the position

of the terminal allows the free passage of air across it at all

times.

The boiler is suitable for installation against a combustible

wall e.g. wood cladding, provided that 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 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 advice must be sought from Potterton.

RSLboilersmaybeinstalledin anyroom,althoughparticular

attention is drawn to the requirements of the current IEE

WiringRegulations and,inScotland,theelectricalprovisions

of the Building Standards applicable in Scotland with

respect to the installation of the boiler in a room containing

a bath or shower.

CFL boilers must not be installed in bath, shower rooms, or

rooms used as sleeping accommodation.

RSLModels:

Wherearoom-sealedapplianceisinstalledin

a room containing a bath or shower, any electrical switch

orappliancecontrol, utilising mains electricity should beso

situated that it cannot be touched by a person using the

bath or shower.

CFL Models:

Conventional flue boilers can be installed

either in a kitchen or utility room or inside a suitably

ventilated, purpose designed or modified compartment.

Where the installation of the boiler will be in an unusual

position,specialproceduresmaybenecessary andBS6798

and BS5546 give detailed guidance on this aspect.

Acompartmentused to enclosetheboilermustbedesigned

and constructed specifically for this purpose. An existing

compartment may be used provided that it is modified for

the purpose. Details of essential features of compartment

design including airing cupboard installations are given in

BS6798 and BS5546 and should be complied with.

RSLModels:

Iftheboilerisfittedunderaworksurfaceitmay

be located next to or between kitchen cabinets or fittings

providing that the front of the boiler case is visible and

unobstructed, the special requirements for an enclosed

compartment will not apply

If the boiler is to be fitted under a worksurface, the

worksurface may need to be removed to install the boiler.

It is advisable that the worksurface be removable to allow

access for servicing if required.

If the boiler is to be fitted in a run of kitchen units it is

recommended that the boiler is fitted first or the adjacent

units removed.

Publication No. 5102977 7Installation Requirements

The boiler requires the clearances shown in Fig. 2.

Conventional Flue Models - See Page 7 & 8.

Balanced Flue Models - See Pages 9 & 10.

Conventional Flue Models

1.4 Air Supply

The air requirements must meet BS 5440 Part 2.

Theroom in which the boiler is installedmust be ventilated.

Ventilation of the room containing the boiler shall include

air for combustion and correct operation of the flue (ie

Draught Diverter dilution).

A permanent air vent shall be provided in an outside wall

of the building either at high or low level in accordance with

Table 1.

The opening may be:

a) Directly into the room or space containing the boiler

or indirectly via an opening of at least the same

area.

b) Via a duct either directly into the room or space or

indirectly via an opening of at least the same free

area.

Where air is drawn indirectly from outside through more

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 required in the compartment, one at high level

and one at low level (Table 2), either direct to the outside

air or to a room.

Both high level and low level air vents must communicate

with the same room or must be on the same wall to outside

air.

If the boiler is installed in a compartment with a door, allow

at least 25 mm clearance between the front of the boiler

and door for air movement. All other clearances are as Fig.

Fig. 3

Table 1

Combustion Air

Free Area cm sq.

CFL40 35

CFL50 51

CFL60 68

CFL70 84

CFL80 101

CFL90 117

CFL100 134

Table 2

Compartment Ventilation

Free Area cm sq. High Level Low Level

CFL40 132 264

CFL50 165 330

CFL60 198 396

CFL70 231 462

CFL80 264 528

CFL90 297 594

CFL100 331 662

Publication No. 5102977

1.5 Flue Systems

A flue system (lined throughout its length) must be

provided to evacuate the flue products of combustion

from the boiler. Reference should be made to the

building regulations and BS 5440:1. and the flue

system efficiency should be checked in accordance

with BS 5440.

Ideally a flue should rise vertically and any terminal or

terminationpoint shallbepositionedsothatcombustion

products can disperse safely at all times. Therefore

forpracticalpurposes,theflueshouldhavetheshortest

possible run to external atmosphere, with as near

verticalriseaspossible,90°bendsshouldbeavoided.

The terminal must be at least above roof level and of

a type approved by British Gas.

To achieve the best perfomance from the boiler there

should be at least 600 mm of vertical flue from the

boiler flue socket. If this is not achievable, a 125 mm

fluesizeshould be used irrespective of theboilersize.

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 models and 125mm for the 70

to 100 models.

Care should be taken to avoid condensation in the

flue.

Inthecase ofapre-linedchimney, itmustbeconnected

to the socket of the boiler flue hood with a length of

purpose made flue.

Wherefluesize is to be determined bycalculation,the

following information should be used

Next Section is 1.6 The System.

Installation Requirements

Fig. 4

Model

Size

100

Mass Rate of Combustion

Products (g/sec)

10.19

11.30

13.58

14.88

15.90

16.55

17.59

Average

Temp. (°C)

108

117

130

135

144

156

165

Seal

Liner

Approved

Ter mi nal

Cement

Seal Sealing

Plate

Set Into

Chimney

Pre-lined Flue

Seal

CON0011C

Purpose

Made

Flue

Purpose

Made Flue

Publication No. 5102977 9Installation Requirements

Balanced Flue Models

1.4 Air Supply

The air requirements must meet BS 5440 Part 2.

The room in which the boiler is installed does not require a

purpose provided air vent.

If the boiler is installed in a compartment, permanent air

vents are required in the compartment, one at high level

and one at low level, either direct to the outside air or to a

room. Both high level and low level air vents must

communicate with the same room or must be on the same

wall to outside air. Both the high level and low level vent

must each have a combined free area in accordance with

Table 3.

If the boiler is installed in a compartment with a door, allow

atleast25mmclearancebetweenthe front of the boiler and

the door for air movement.

1.5 Flue 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.

A1m flueextensionisavailable.Undernocircumstances

should the total flue length exceed:-

3.4m 40 to 70 models

2.4m 80 model

1.4m 90 model

1.0m 100 model

Vertical - Concentric.

3.4m 40 - 70 models Only

Where bends may be being used, the total flue length will

be reduced, see Pages 17 & 18 for more details.

See separate Installation Instructions supplied with the

flue.

Fig. 5

Table 3

Compartment Ventilation

Free Area cm sq. High Level Low Level

RSL40 132 132

RSL50 165 165

RSL60 198 198

RSL70 231 231

RSL80 264 264

RSL90 297 297

RSL100 331 331

Note: If ventilating directly to outside, the figures shown in

Table 3 can be halved.

Publication No. 5102977

• Where a horizontal flue is sited less than 2m

above a balcony, above ground, or above a flat

roof to which people have access, a suitable

terminal guard must be fitted. This serves two

purposes, to protect the terminal against damage

or interference and to protect passers-by. A

terminal guard is available (Sales Code:

PTERMGUARDEF), this should be fitted centrally

about the terminal.

Note: Where a flue terminal is installed less than

1 metre from a plastic, or painted gutter, or 500

mm from painted eaves, an aluminium shield 1

metre long, should be fitted to the underside of the

gutter or painted surface. A suitable wall plate

should be fitted to the painted wall surface of a

mobile home.

• IMPORTANT: It is absolutely ESSENTIAL, to

ensure that products of combustion discharging

from the terminal cannot re-enter the building, or

any other adjacent building, through ventilators,

windows, doors, natural air infiltration, or forced

ventilation/air conditioning. If products of

combustionarefound to bere-enteringany building,

the appliance MUST be turned OFF

IMMEDIATELY.

Installation Requirements

Fig. 6

AAF

K,N

Likely flue positions requiring

a flue terminal guard

K,N

FLU0002A

FannedDraughtBalancedFlue

ADirectly below an opening, air brick,

opening window etc

BAbove an opening, air brick, opening window, etc

CHorizontally to an opening, air brick,

opening window etc

DBelow a gutter, or sanitary pipework

EBelow the eaves

FBelow a balcony or carport roof

GAbove ground, roof or balcony level

HFrom vertical drain/soil pipe work

JFrom an internal or external corner

KFrom a surface facing a terminal

LVertically from a terminal on the same wall

MHorizontally from a terminal on the same wall

NFrom a terminal facing the terminal

PFrom an opening in a

carport

(e.g. door, windows)

into the

building

QFrom adjacent wall to flue (vertical only)

RFrom internal corner to flue (vertical only)

SBelow eaves or balcony (vertical only)

Terminal Position with Minimum Distance (mm)

Note: The distance from a fanned draught appliance terminal installed

parallel to a boundary may not be less than 300 mm in accordance with

the diagram on the left.

300

200

300

150

300

600

1500

300

1200

210

230

600

Top View Rear Flue Top View Side Flue

Terminal

Assembly

Property Boundary Line

Fanned DraughtFanned Draught

300 min. 300 min.

FLU0005A

Reduced Clearances

This range of boilers has been tested and approved for use with certain

clearances less than those shown above.

Only one of these reductions may be used on a single installation.

RSL40-70 RSL80-100

DBelow a gutter, or sanitary pipework 25 25

EBelow the eaves 25 25

FBelow a balcony or carport roof 25 25

HFrom vertical drain/soil pipe work 25 ---

JFrom an internal or external corner 25 ---

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