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O Potterson CF 20/35 Installation And Servicing Instrucnions

Open flue gas fired boiler
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CF 20/35 CF 35/50
Open Flue Gas Fired Boiler
THIS APPLIANCE IS FOR USE WITH NATURAL GAS ONLY.
Installation and Servicing Instructions
LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.
Page 1
Page 2
FLAMINGO CF 20/35 G.C. No. 41 .605.59
35/50 G.C. No. 41 .605.60

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  • Page 1 Open Flue Gas Fired Boiler THIS APPLIANCE IS FOR USE WITH NATURAL GAS ONLY. Installation and Servicing Instructions LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER. Page 1 Page 2 FLAMINGO CF 20/35 G.C. No. 41 .605.59 35/50 G.C. No. 41 .605.60...

  • Page 2: Table Of Contents

    IMPORTANT This appliance must be installed by a competent person as stated in the Gas Safety (Installation and Use) Regulations 1984. Flamingo boilers are certified by BSI for safety. It is therefore important that no external devices (e.g., flue dampers, economisers etc.) be directly connected to theseappliances unless covered by these installation instructions or otherwi se recommended in writing.

  • Page 3: Accessories

    or use on sealed or open vented gravity hot water/pumped central heating sys tems orfully pumped systems. ACCESSORIES The following range of Potterton system controls are also available and further information will be provided upon request. Electronic Programmer EP. 2000, E.P. 3000, E.P. 4000. Programmable Electronic Thermostat PET 1 Thermostatic Radiator Valve PV456 and PH456 Electronic Cylinder Thermostat PTT 1...
  • Page 5 Page 4 INSTALLATION DATA - Page 5 FIG. 2. GENERAL ARRANGEMENT...
  • Page 6 Page 5...

  • Page 7: Site Requirements

    SITE REQUIREMENTS - Page 6 These boilers are not suitable for external installation. This appliance must not be installed in bathrooms, shower rooms, bedrooms, bed- sitting rooms, garages or rooms where highly inflammable materials or vapour s are likelyto be present. Fitting in toilets or cloakrooms is not recommended b ut it is permitted, provided the ventilation and combustion air is taken direct fro m outside.
  • Page 8 CF 35/50 High CF 20/35 High There must be at least 300mm (12in) clearance between the grille on the front of the boiler casing and any internal surface of the cupboard to allow for adeq uate air foroperation of the draught diverter.
  • Page 9 The minimum effective area of the permanent air vent must be: CF 35/50 56 cm² 9 in² CF 20/35 30 cm² 4.9 in² If the room (e.g. kitchen) from which air is drawn, has an extract fan fitted, the n the opening size of the permanent air vent should take this into account to e nsure that theoperation of the boiler flue is not adversely affected when the ex traction fan is running with all doors and windows closed.

  • Page 10: Technical Data

    ld be avoided. The terminal must be at least above roof edge level and must b e of a type acceptableto British Gas. Whever possible there should be at least 2 ft (600mm) of vertical flue from the boiler flue socket. NOTE: A split socket should be fitted in this length.
  • Page 11 - 82ºC Maximum Flow Temperature Electricity Supply 240V ~ 5OHz fused at 3A Water Connections - R ¾ (¾ in BSP Male) Gravity Flow Gravity Return to injector ‘Tee’ - To accept 28mm copper - R.c. 3¾ Pumped Flow (¾ in BSP Female) Pumped Return using injector ‘Tee’...
  • Page 12 CIRCULATION PUMP SELECTION The resistance through the heat exchanger when operating with a water flow r ate producing an 11º C temperature rise at maximum boiler output is shown in TABLE 2. If othercontrols, such as three position valves are used in the syste m, the resistance through them, quoted in their manufacturer’s literature must be taken into account.
  • Page 13 TECHNICAL DATA - Page 9 THE SYSTEM The boiler must be used on Indirect hot water systems only. It is suitable for u se on sealed or open vented gravity domestic hot water/pumped central heati ng systems or fullypumped systems. The system should be designed so that the maximum static head does not ex ceed 30.5m (100 ft) and a minimum on fully pumped systems of 305mm (1 ft.) .
  • Page 14 wn in FIG. 6 where the bathroom radiator is connected into the gravity circuit a nd is fitted with two lockshield valves. Fully Pumped Systems The pump must always be wired directly to the boiler terminal block as shown FIG. If a three port diverter valve is used as shown in FIG.
  • Page 15 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 sys tem, preferably atthe same point as the expansion vessel. Its location should be visible from the filling point.
  • Page 16 Initial System Pressure (bar) Expansion Vessel Volume V X 0.11 V X 0.087 (litres) Cylinder The hot water cylinder must be an indirect coil type or a direct cylinder fitted wi th an immersion calorifier suitable for operating at a gauge pressure of 0.3 bar (5 lbf/in²) inexcess of safety valve setting.
  • Page 17 FIG. 4 OPEN VENTED FULLY PUMPED SYSTEM FITTED WITH A COMBIN ED FEED AND VENT Page 10 TECHNICAL DATA - Page 11...
  • Page 18 FIG. 5. FULLY PUMPED SEALED SYSTEM FIG. 6 OPEN VENTED GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING SYSTEM...

  • Page 19: Installation Instructions

    Page 11 INSTALLATION INSTRUCTIONS - Page 12 The boiler and its associated equipment will arrive on site in two cardboard ca rtons. The contents of each carton is as follows: CARTON 1 CARTON 2 Boiler Literature Pack containing: Case Support Plate Installation and Servicing Instructions User’s Instructions Boiler Mounting Bracket...
  • Page 20 (the minimum side clearances areautomatically allowed for). Refer to page 6 or top and bottom clearances which can be measured from the template. Ensure that the template is level and mark hole positions ‘A’. ‘B’, and centre of boiler reference line through the slot in the bottom edge of th e template.
  • Page 21 INSTALLATION INSTRUCTIONS - Page 13 LIFTING THE BOILER Lift boiler on to its mounting bracket and centralise it by aligning the notch in t he heat shield at the bottom of boiler with the reference line on wall. Correct vertical alignment with the rear wall as necessary using the adjustmen t screws fitted to the boiler legs.
  • Page 22 To ensure that the flow and return pipes will pass through the cut- outs provided in the top and bottom of the case all pipes should be routed as s hown in FIGS. 10a, b. Ifrequired a 22mm copper pipe can be routed down eac h side of the boiler within the casing.
  • Page 23 FIG. 10b. FULLY PUMPED SYSTEM FIG. 11. PRINCIPLE OF WIRING WARNING: This appliance must be earthed. The boiler and all external control circuit wiring must be supplied from the sam e single isolating switch or plug and socket. Care must be taken to ensure that all wiring to the boiler is kept clear of sharp edges and hot surfaces.
  • Page 24 The principle of wiring is shown in FIG. 11. It should be noted that the pump m ust be wired directly to the boiler terminal block on FULLY PUMPED systems and to thejunction box or programmer on combined GRAVITY HOT WATER/P UMPED CENTRAL HEATING systems.
  • Page 25 FIG. 13. WIRING THE BOILER FOR A COMBINED GRAVITY HOT WATER/ PUMPED CENTRAL HEATING SYSTEM Pull off the boiler thermostat knob. See FIG. 2. Remove two screws securing control panel cover and remove cover. Route a three core cable through the plastic bush in the rear of the control pan el and the cable clamp as illustrated in FIG.

  • Page 26: Commissioning

    FIG. 15. BOILER WIRING DIAGRAM Page 15 COMMISSIONING - Page 16 Open Vented Systems Remove the pump and flush out the system thoroughly with cold water. Refit t he pump, fill and vent the system and examine for leaks. Sealed Systems The system can be filled using a sealed system filler pump with a break tank o r by any other method approved by the Local Water Authority.
  • Page 27 B Turn the boiler thermostat to the ‘O’ position. C Turn on the main gas supply and the gas service cock on boiler. Ensure that the time control, if fitted is in an ‘ON’ condition, and that the room and/or cylinder thermostats, where fitted are set to high temperatures. E Switch on the external electricity Supply to the boiler.
  • Page 28 Check soundness of all appliance gas carrying components and joints using le ak detection fluid and a mirror where necessary. K Switch off the boiler, using the thermostat knob. FINAL ADJUSTMENT A Remove the screw from the burner pressure test nipple on the gas control v alve and fit a pressure gauge to the test nipple.
  • Page 29 COMMISSIONING - Page 17 FIG. 16. GAS CONTROL VALVE FIG. 17. PILOT BURNER Pilot Burner The pilot burner pressure is non- adjustable. The pilot flame should heat the thermocouple so that the pilot safet y device is "held in" but must not cause the thermocouple toglow bright red. G.
  • Page 30 At its minimum and maximum settings, the thermostat should control the wate r flow temperature at approximately 55ºC-82ºC (130º F- 180º F). The thermostat has beencalibrated by the makers and no attempt sh ould be made to re- calibrate it on site. Turn the thermostat to the ‘O’ position and check that the m ain burner shuts down.
  • Page 31 Expose the lower case fixings by lowering the door in the front of case. This is done by pressing the release lever through the hole in the underside of the ca Locate the holes in the case over the threaded studs attached to the combusti on chamber front panel and secure using two M5 nuts from accessory pack C.
  • Page 32 SERVICING INSTRUCTIONS - Page 19 To ensure continued safe and efficient operation of the boiler, it is necessary t o carry out servicing and cleaning at regular intervals. The frequency of cleani ng will dependupon the particular installation conditions, and the use to which the boiler is put, but in general, once per year should be adequate.
  • Page 33 D Remove the two main burner securing screws, lift out the main burner and g as control assembly. E Unscrew the M5 nut on CF 35/50 or hexagonal locating peg on CF 20/35 w hich secure the burner end cap. Remove burner end cap. Withdraw the intern al baffle and gauzefrom within the burner.
  • Page 34 SERVICING INSTRUCTIONS - Page 20 FIG. 19. BURNER AND GAS CONTROL ASSEMBLY FIG. 20. DRAUGHT DIVERTER AND FLUE BAFFLE ASSEMBLY 3. HEAT EXCHANGER Remove the four securing screws and withdraw the inner draught diverter ass embly from the mouth of the draught diverter. See FIG.
  • Page 35 C Working from above and below the heat exchanger, use a suitable flue brus h and remove all of the deposits from between the fins. D Refit the baffles into the outer two flueways. E. Refit the inner draught diverter assembly, securing it with the four screws. 4.
  • Page 36 MAIN BURNER Refer to FIG. 19 and carry out the following: a) Switch off the external electricity supply by disconnecting the plug at the so cket or switching off external isolating switch. b) Carry out operations A and B as described in section 1 PREPARING THE BOILER FOR SERVICING.

  • Page 37: Servicing Instructions

    This operation is most easily carried out by first removing the burner and gas control valve assembly as follows:- Switch off the external electricity supply by disconnecting the plug at the sock et or switching off external isolating switch. Remove boiler case and combustion chamber front panel as described in REPARING THE BOILER FOR SERVICING operations A and B.
  • Page 38 The pilot burner is protected from blockage by a pilot filter situated within the g as control valve. The filter is large and designed to last the life of the gas contr ol valve undernormal operating conditions. It is therefore unlikely to need repla cing.
  • Page 39 b) Remove boiler case and combustion chamber front panel as described in s ection 1 PREPARING THE BOILER FOR SERVICING operations A and B. c) Remove the burner assembly as described in section 2. MAIN BURNER AS SEMBLY - REMOVAL AND CLEANING operations A, B, C, D.
  • Page 40 Replacement is the reverse of removal. Ensure that the end of the electrode le ad covered with black sleeving is att ached to the spark generator and that the lead iscorrectly replaced in the split grommet. SPARK GENERATOR a) Switch off the external electricity supply by disconnecting the plug at the so cket or switching off external isolating switch.
  • Page 41 a) Switch off the external electricity supply by disconnecting the plug at the so cket or switching off external isolating switch. b) Remove boiler case as described in section 1 PREPARING THE BOILER F OR SERVICING operation A. c) Remove locking nut securing thermostat to control panel. d) Disconnect the two blue wires from the thermostat terminals.
  • Page 42 Burner injector, 3.5mm 410967 337 376 Spark generator, VERNITRON 407693 382 887 Boiler thermostat, RANCO 404496 381 839 Overheat thermostat, RANCO 404492 381 753 Boiler thermostat knob 214239 337 629 Flue brush (optional extra) 212154 337 526 Main Burner Gasket 214006 337 682 Gas Manifold Gasket...
  • Page 43 Page 25...

This manual is also suitable for:

Cf 35/50

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