Potterton Kingfisher Mf Installation and maintenance instructions

Installation & Service Instructions Kingfisher Mf
RSL40 - 100, CFL40 -100
Flame Lock-out Re-set
0
This is a Floor Mounted Fan Assisted Gas Boiler and is available as Conventional or Balanced Flue
The boiler meets the requirements 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 and for use in GB/IE only.

Publication No. 5102977
2
Flame Lock-out Re-set
0
Control Panel Serial Number Badge
CON0092B
Data Badge
50 -100
Data Badge
40
Contents
Contents
Technical Data......................................................3
Introduction..........................................................5
1. Installation Requirements..............................6
2. Installation...................................................15
3. Commissioning............................................22
4. Service & Replacement of Parts..................25
5. Wiring Diagrams............................................30
6. Fault Finding..................................................32
7. Short List of Spares......................................36
8. Flue Kits & Optional Extras..........................38
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
Fig. 1
Benchmark Installation, Commissioning and Service
Record Log Book
Potterton is a member of the Benchmark initiative and
fully supports the aims of the programme. 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.
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
telephoning [phone] or writing to:-
CORGI. 1 Elmwood, Chineham Business Park,
Crockford Lane, Basingstoke, RG24 8WG.
Important - Installation, Commissioning, Service &
Repair
This appliance must be installed in accordance with the
manufacturer’s instructions and the regulations in
force. Read the instructions fully before installing or
using the appliance.
In GB this must be carried out by a competent person
as stated in the Gas Safety (Installation & Use)
Regulations.
Definition of competence: A person who works for a
CORGI registered company and holding current
certificates in the relevant ACS modules, or valid ACoP
equivalents, is deemed competent.
In IE this must be carried out by a competent person as
stated in I.S. 813. "Domestic Gas Installations".
Lifting
Important - This product should be lifted and handled
by two people. Stooping should be avoided, and
protective equipment worn when necessary. Carrying
and lifting equipment should be used as required, for
example when installing in a loft space.
Identification
The boiler model and serial number are given on the
boiler data label which is located on the heat
exchanger cover plate.

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
Burner Pressure 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
Maximum Working Head 30.5 m (3 bar)
Minimum Working Head 300 mm
Minimum Circulating Head - Gravity 1.2 m
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 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
Introduction
Kingfisher Mf boilers are fully automatically controlled, floor
standing, fan powered, balanced or conventional flued
appliances using a cast iron heat exchanger and are
available in outputs ranging from 11.72 - 29.31 kW (40,000
- 100,000 Btu/h).
The boiler meets the requirements 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 and for use
in GB/IE only.
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.
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.
1.1 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.
Man-Made Mineral Fibre
a) Some component parts of this appliance (insulation
pads, gaskets and rope seals) are manufactured from
man-made mineral fibre.
b) Prolonged or excessive exposure to this material may
result in some irritation to the eyes, skin or respiratory
tract.
c) It is advisable to wear gloves when handling these
items.
d) Irritant dust will only be released from the items if
they are broken up or subjected to severe abrasion.
In these instances a suitable dust mask and goggles
should be worn.
e) Always thoroughly 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 in
force.
In GB, the installation must be carried out by a CORGI
Registered Installer. It must be carried out in accordance
with the relevant requirements of the:
•Gas Safety (Installation & Use) Regulations.
•The appropriate Building Regulations either The
Building Regulations, The Building Regulations
(Scotland), Building Regulations (Northern Ireland).
•The Water Fittings Regulations or Water byelaws in
Scotland.
•The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should
be made to the relevant British Standard Codes of Practice.
In IE, the installation must be carried out by a Competent
Person and installed in accordance with the current edition
of I.S. 813 "Domestic Gas Installations", the current
Building Regulations and reference should be made to the
current ETCI rules for electrical installation.
In GB the following Codes of Practice apply:
Standard Scope
B.S. 6891 Gas Installation.
B.S. 5546 Installation of hot water supplies for domestic purposes.
B.S. 5449 Forced circulation hot water systems.
B.S. 6798 Installation of gas fired hot water boilers.
B.S. 5440: Pt 1 Flues.
B.S. 5440: Pt 2 Ventilation.
B.S. 7593 Water Treatment.
B.S. 4814 Expansion vessels for hot water systems.
B.S. 6283 Safety and control devices for use in hot water systems.
In IE
I.S. 813 Domestic Gas Installations
The following BS standards give valuable additional information;
B.S. 5546 Installation of hot water supplies for domestic purposes.
B.S. 5449 Forced circulation hot water systems.
B.S. 7593 Water Treatment.
B.S. 4814 Expansion vessels for hot water systems.
B.S. 6283 Safety and control devices for use in hot water systems.
Warning - The addition of anything that may interfere
with the normal operation of the appliance without
express written permission from the manufacturer or his
agent could invalidate the appliance warranty. In GB this
could also infringe the GAS SAFETY (Installation and
Use) REGULATIONS.

Publication No. 5102977
6 Installation Requirements
1. Installation Requirements
1.1 Gas Supply
The meter and supply pipes must be capable of delivering
this quantity of gas in addition to the demand from any
other appliances in the house and must be governed at
the meter. The pipe diameter required will depend on the
boiler model and the pipe length from the gas 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.
The gas installation should be in accordance with the
relevant standards. In GB this is BS 6891. In IE this is the
current edition of I.S. 813 "Domestic Gas Installations".
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 mm≈(24 x 0.2 mm) (code designation
HO5 VV-F or HO5 VVH2-F) as specified in table 16 of
BS6500:1984.
External wiring must be correctly earthed, polarised and in
accordance with relevant regulations/rules. In GB this is
the current I.E.E. Wiring Regulations. In IE reference
should be made to the current edition of the ETCI rules.
WARNING: THIS APPLIANCE MUST BE EARTHED.
1.3 Location of Boiler
The boiler is not suitable for external installation. The
boiler must stand firm and level. No special floor protection
is needed, but finishes which soften when warm e.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 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 Installation in Timber Framed Housing).
If the boiler is to be fitted in a room containing a bath or
shower reference must be made to the relevant
requirements.
In GB this is the current I.E.E. Wiring Regulations and
Building Regulations.
In IE reference should be made to the current edition of
I.S. 813 "Domestic Gas Installations" and the current ETCI
rules.
CFL boilers must not be installed in bath, shower rooms,
or rooms used as sleeping accommodation.
RSL Models: Where a room-sealed appliance is installed
in a room containing a bath or shower, any electrical
switch or appliance control, utilising mains electricity
should be so 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, special procedures may be necessary and
BS6798 and BS5546 give detailed guidance on this
aspect.
A compartment used to enclose the boiler must be
designed 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.
RSL Models: If the boiler is fitted under a worksurface it
may 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.
The room in which the boiler is installed must 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. 2.
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
8
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 termination point shall be positioned so that
combustion products can disperse safely at all
times. Therefore for practical purposes, the flue
should have the shortest possible run to external
atmosphere, with as near vertical rise as possible,
90°bends should be avoided. 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 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 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.
In the case of a pre-lined chimney, it must be
connected to the socket of the boiler flue hood with
a length of purpose made flue.
Where flue size is to be determined by calculation,
the following information should be used
Next Section is 1.6 The System.
Installation Requirements
Fig. 4
Model
Size
40
50
60
70
80
90
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

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 at least 25mm clearance between the 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.
A 1m flue extension is available. Under no
circumstances 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
10 Installation Requirements
Fig. 6
N
I
I
G
F
M
I
AAF
H
J,K
D
E
H
Likely flue positions requiring
a flue terminal guard
C
R
A
I
J,K
I
FLU0002A
L
T
S
B
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.
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 ---
The following guidelines indicate the general requirements
for siting balanced flue terminals.
For GB recommendations are given in BS 5440 Pt. 1.
For IE recommendations are given in the current edition of
I.S. 813 "Domestic Gas Installations"..
If a terminal is less than 2m above a balcony, above
ground, or above a flat roof to which people have access,
then a suitable terminal guard must be fitted. A terminal
guard is available (Part No. 205792), this should be fitted
centrally about the terminal.
If the terminal discharges onto a pathway or passageway,
check that the combustion products will not cause a
nuisance and that the terminal will not obstruct the
passageway.
If the flue terminal is fitted 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, or any other adjacent building,
through ventilators, windows, doors, natural air infiltration,
or forced ventilation/air conditioning. If products of
combustion are found to be re-entering any building, the
appliance MUST be turned OFF IMMEDIATELY.
Fanned Draught Balanced Flue
AaDirectly below an opening, air brick,
opening windows, etc.
BaAbove an opening, air brick, opening window, etc.
CaHorizontally to an opening, air brick,
opening window, etc.
DBelow gutters, soil pipes or drain pipes.
EBelow eaves.
FBelow balconies or car port roof.
GFrom a vertical drain pipe or soil pipe.
HFrom an internal or external corner.
IAbove ground, roof or balcony level.
JFrom a surface facing a terminal.
KFrom a terminal facing the terminal.
LFrom an opening in a carport (e.g. door, window)
into the dwelling.
MVertically from a terminal on the same wall.
NHorizontally from a terminal on the same wall.
RFrom adjacent wall to flue (vertical only).
SFrom internal corner to flue (vertical only).
TBelow eaves or balcony (vertical only).
Terminal Position with Minimum Distance (mm)
For IE, refer to I.S. 813 "Domestic Gas Installation".
aIn addition, the terminal should not be nearer than 150 mm to an opening
in the building fabric formed for the purpose of accommodating a built-in
element such as a window frame. See BS 5440 Pt. 1.
75
200
200
150
300
300
600
1200
1200
1500
300
210
230
600
300
300
300

Publication No. 5102977 11Installation Requirements
1.6 The System
If plastic pipe is used for the central heating circuit there
must be a run of at least 1m of uninsulated copper pipe
from the boiler flow and return connections.
The boiler must be used on INDIRECT hot water
systems only. It is suitable for use on open vented gravity
domestic hot water/pumped central heating systems or,
fully pumped systems which may be sealed or open
vented.
Before installing a new boiler to an existing system treat
the system with an appropriate descaling/flushing agent
as per the instructions supplied with the treatment
package. It is recommended that any corrosion inhibitors
and descalers/flushing agents used are manufactured
by Fernox or BetzDearborn
The system should be designed so that the maximum
static head does not exceed 30.5 m and there is a
minimum on fully pumped systems of 300 mm. See Fig.
9.
Gravity domestic hot water circuits should have a
minimum circulating head of 1.2 m. See Fig. 8.
Horizontal pipe runs should be kept to a minimum. To
prevent reverse circulation in the gravity circuit when the
pump is running an injector tee is incorporated.
The pump should preferably be fitted in the flow, though
installation in the return is acceptable providing care is
taken to ensure air is not drawn into the system due to
the negative pressure effects of the pump. Isolating
valves must be fitted as close as possible to allow
replacement without system draining.
Drain off taps should be fitted in the pipework close to
the boiler and in the low points of the system. A drain
point is also provided on the heat exchanger should the
boiler need draining - see Fig. 22.
Combined Gravity Hot Water Pumped Central
Heating Systems.
It is recommended that a cylinder thermostat and zone
valve are used to control the temperature of the hot
water and that a by-pass be installed in the gravity
circuit. A suggested method of doing this is shown in Fig.
8. where the bathroom radiator is connected into the
gravity circuit and is fitted with two lockshield valves.
Mechanically operated thermostatic domestic hot water
temperature control valves which allow the boiler to
operate when the valve is closed or partially closed
MUST NOT BE FITTED UNLESS a bypass radiator is
fitted. Note: The boiler has one 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 thus preventing
nuisance operation of the overheat thermostat.
If a three port diverter valve is used as shown in Figs.9 &
10, a by-pass is not necessary since one circuit is always
open. Where a pair of two port valves are used, a by-
pass is necessary. It should be fitted with a lockshield
valve and be adjusted to maintain a minimum flow
through the boiler of 4.5 litres/min (1 gal/min) see Figs. 9
& 10.
Systems fitted with controls which allow the boiler to
operate when both the hot water and central heating
circuits are closed i.e. mechanically operated
thermostatic control valves, must be fitted with a by-pass
circuit capable of:-
1. Dissipating a minimum of 1kW (3,400 Btu/h)
2. Maintaining a minimum water flow through the
boiler of 9 litres/min (2 gal/min).
A suggested method of meeting these requirements by
using a bathroom radiator fitted with two lockshield
valves is shown in Figs. 9 & 10.
Diagrammatic layouts of a fully pumped system and a
combined pumped central heating/gravity hot water
system are shown in Figs. 8 & 9.
Sealed Systems (Fully Pumped)
Installation
The installation must comply with the requirements of BS
6798: 1987 and BS 5449: Pt 1. The British Gas
publication "British Gas Specification for Domestic Wet
Central Heating Systems" should also be consulted.
Safety Valve
A non-adjustable spring-loaded safety valve, preset to
operate at 3 bar (45lbf/in2) shall be used. It must comply
with BS 6759: Pt 1. and include a manual testing device.
It shall be positioned in the flow pipe either horizontally
or vertically upwards and close to the boiler. No shut-off
valves are to be placed between the boiler and the safety
valve. The valve should be installed into a discharge pipe
which permits the safe discharge of steam and hot water
such that no hazard to persons or damage to electrical
components is caused.
Pressure Gauge
A pressure gauge incorporating a fill pressure indicator,
covering the range 0 - 4 bar (60 lbf/in2) shall be fitted to
the system. It should be connected to the system,
preferably at the same point as the expansion vessel. Its
location should be visible from the filling point.

Publication No. 5102977
12 Installation Requirements
Cylinder
The hot water cylinder must be an indirect coil type or a
direct cylinder fitted with an immersion calorifier suitable
for operating at a gauge pressure of 0.3 bar (5 lbf/in≈) in
excess of safety valve setting. Single feed indirect
cylinders are not suitable for sealed systems.
Method of Make-up for sealed systems
An alternative method of replacing water lost from the
system could be provided by means of a make up vessel
of not more than 3 litres capacity, mounted above the
highest point of the system.
Mains Connection
There shall be no connection to the mains water supply
or to the water storage tank which supplies domestic hot
water even though a non-return valve, without the
approval of the Local Water Authority.
Filling Point
A filling point connection on the central heating return
pipework must be provided to facilitate initial filling and
pressurising and also any subsequent water loss
replacement/refilling.
The sealed primary circuits may be filled or replenished
by means of a temporary connection between the circuit
and a supply pipe, provided a ‘Listed’double check valve
or some other no less effective backflow prevention
device is permanently connected at the inlet to the circuit
and the temporary connection is removed after use.
The filling method adopted must be in accordance with
all relevant water supply regulations and use approved
equipment.
Your attention is drawn to, for GB: Guidance G24.2 and
recommendation R24.2 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 vessel to BS 4814: Pt 1.
shall be fitted close to the inlet side of the pump. The
connecting pipework should not be less than 15mm.
Pipework connecting the expansion vessel should not
incorporate valves of any sort. Methods of supporting the
vessel are supplied by the vessel manufacturer. The
nitrogen or air charge pressure of the expansion vessel
shall not be less than the hydrostatic head, (height of the
top point of the system above the expansion vessel).
To size the expansion vessel it is first necessary to
calculate the volume of water in the system in litres. The
following volumes may be used as a conservative guide
to calculating the system volume.
Boiler Heat Exchanger: 6.5 litres
Small Bore Pipework: 1 litre per kW of system
output
Micro Bore Pipework: 7 litres
Steel Panel Radiators: 8 litres per kW of
system output
Low Water Capacity Radiators: 2 litres per kW of
system output
Hot Water Cylinder: 2 litres
If the system is extended, the expansion vessel volume
may have to be increased unless provision has been
made for extension.
Where a vessel of the calculated size is not available, the
next available larger size should be used.
The boiler flow temperature is controlled at
approximately 82°C.
The vessel size can now be determined from the
information in Table 4 where V = System volume in litres.

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

Publication No. 5102977
14 Installation Requirements
CON0015C
Fully Pumped Sealed System
Fig. 10
Circulation Pump Selection
The resistance through the heat
exchanger when operating with a
water flow rate producing an 11°C
temperature rise at maximum boiler
output 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. On fully pumped
systems either return connection may
be used.

Publication No. 5102977 15
2. Installation
2.1 Install the boiler
These instructions assume you have decided
on where the boiler will be located and the
type of flue system to be used.
1. Carefully unpack the boiler. Remove and
place aside the tailpipe/gravity stat kit and
on CFL boilers, the ancillary bag
containing the top and rear blanking
plates with seal and control panel.
2. Do not discard any packaging until all the
items are accounted for.
3. Temporarily position the boiler to ensure
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
2.2 Install the flue
Install the flue type as required.
Conventional Flue:
1. Loosen the 4 screws securing the flue
spigot to the boiler, line the spigot up with
the flue and fully tighten the screws.
Note: From its fully rearward position the
spigot will move forward 50mm.
CON0021F
Fig. 11

Publication No. 5102977
16 Installation
Fig. 14
Centre of
the Flue
Cut Out Hole
Front Edge
Rear Edge
Top View of the Work top
Minimum
from Wall
Maximum
from Wall
135
Max.
C/L. C/L.
115
85 Minimum
200
200
100
100
200
200
CON0075A
2. Attach the flue to the flue spigot.
This product is fitted with a combustion
products discharge safety device (TTB)
which must not be taken out of operation
at any time. The component is fitted to
ensure that any blockage or partial
blockage of the flue does not result in
combustion products discharging into the
room.
Fitting under a Worktop (CFL Models)
1. Remove the top blanking plate from the
boiler (if 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 mm from the wall and a
maximum of 135 mm from the wall being
dependent on the boiler position.
5. Place boiler in position under the work
top.
6. Re-fit the flue spigot as shown in Fig. 13.
7. Refit the products discharge safety device
(TTB) back onto the flue spigot and
secure with the screw.
IMPORTANT: Ensure the Products
Discharge Safety Device (TTB) is
repositioned correctly and secvured to
the dimension shown in Fig. 28, Page 29.
Fig. 13

Publication No. 5102977 17
Fitting the Blanking Plate
1. If the flue is not fitted in the fully forward
position, the rear blanking plate will need
to be cut to size, cut trim to length as
required. See Fig. 15.
•If fitting under a worktop then drill 2
pilot holes through the holes in the rear
blanking plate plate and into the work
top. Secure the plate using 2
woodscrews (not supplied).
2. Locate the top blanking plate as shown in
Fig. 15.
Balanced Flue:
1. Mark the flue outlet hole position on the
wall as illustrated.
Note: Ensure that the correct allowance is
made for side outlet when the boiler is not
being pushed fully back.
2. Carefully cut hole through wall.
Maximum flue lengths are as follows:
40 - 70 models 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 gap in the
wall cavity.
7. Slide the flue through the hole until it
stops on the pin.
8. The boiler is supplied with the flue elbow
set for the rear. For side outlet slacken the
screws, turn the elbow as required and
retighten screws.
Note: Ensure that the seals are still
correctly located.
Air Box
Top Edge of
Work top
Cut
Out
Hole
Top of
Boiler
Work top
CON0076A
Fit Top
Blanking
Plate
Refit Flue
Spigot
Cut to size
(if required) Fit Trim
Screw Rear
Blanking Plate
to work surface
Installation
Fig. 16
Fig. 15

Publication No. 5102977
18 Installation
9. Slide the flue back until it engages in the elbow
bayonet connection, twist clockwise to lock.
10.Drill through pilot hole and lock flue in position
using the self tapping screw provided.
11.Make good the wall around the flue, both inside
and outside.
For optional extras refer to Page 38 & 39. If a
Horizontal Extension is required this MUST be
combined with a Standard Flue as 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
telescopic length, the tubes can be cut to suit.
Ensure that the same length is removed from
the inner and outer tubes to maintain a
minimum 20 mm overlap.
For further information see publication
'Combination Flues'.
Fig. 17

Publication No. 5102977 19Installation
Fig. 19
2.3 Connect the Gas Supply
1. Ensure that the gas supply is isolated.
2. Disconnect the gas cock from the gas
valve.
3. Connect the gas supply to the gas cock
using a suitable adaptor.
Important:
Do not solder the fitting whilst
assembled to the gas cock.
.
4. Connect the gas cock to the gas valve.
Do not turn the gas supply on at this
stage.
2.4 Connect the Water System
When attaching the standard pipe connecting kit to the boiler please note that the seal is made by use of an 'O' ring,
therefore some pipe 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. Note: Drain off taps should be installed at the lowest points in the system.
2. If on a Gravity DHW system position the overheat thermostat as shown.
3. To do this - unscrew the overheat thermostat from the flow pipe and re-attach as shown using the bracket and screw
found in the tail pipe/gravity stat kit.
Return
(Pumped)
Return
(Pumped)
CON0020D
Fig. 18

Publication No. 5102977
20 Installation
Fig. 20
2.5 Connect the Power Supply Cable
1. Cable clamping is provided on the front of
the controls panel. Feed the cables up
and over the back of the chassis, through
the clamp and into the terminal
connection.
Note: When connecting the power supply
cable, ensure that the length of the earth
wire is such, that if the power supply
cable pulls out of the cable clamp the live
and neutral wires become taut before the
earth wire.
If fitting the optional integral programmer,
refer to the instructions supplied with it for
wiring details.
For Gravity DHW/Pumped CH Systems,
the pump should be wired externally.
For Fully Pumped Systems, 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 terminal MAINS 'L'
b. Switched live from external controls to
MAINS 'SwL'.
c. Neutral to MAINS 'N'.
d. Earth to MAINS 'E'.
e. Pump to PUMP 'L, N, E'.
Open Vented Fully Pumped Systems
The boiler is fitted as standard with an
overheat thermostat and pump overrun
device which requires a permanent live to
the boiler. This is the recommended
installation method (see above).
However, in replacement situations where
a permanent live is not available, it is
possible to wire the boiler with 3 core