Potterton 80e, Installation & Service Instructions Manual

Contents

Technical Data............................................................ 3
Introduction ................................................................ 4
Optional Extras .......................................................... 5

1.

Installation Requirements ......................................... 8

1.1

General Information........................................... 8

1.2

Location of Boiler ............................................... 7

1.3

Flue Terminal and Ducting...............................10

1.4

Air Supply ........................................................10

1.5

Guide to System Requirements.......................11

1.6

Mains Water Feed C.H ....................................12

1.7

Installation to an Existing System....................12

1.8

Hard Water Areas............................................12

1.9

Pump Performance Curve ...............................13

1.10 Electrical Supply ..............................................14
1.11 Clearance Around the Appliance .....................15

2.

Boiler Installation.....................................................16

2.1

Unpacking........................................................16

2.2

Gas Connection. ..............................................17

2.3

D.H.W Supply ..................................................17

2.4

C.H. Supply......................................................17

2.5

Pressure Relief Valve ......................................18

2.6

Wiring the Appliance........................................18

3.

Commissioning ........................................................19

3.1

Electrical Installation ........................................19

3.2

Gas Installation................................................19

3.3

Initial Lighting...................................................20

3.4

Gas Pressure Adjustment................................21

3.5

Products of Combustion Measurement ...........22

3.6

D.H.W Flow Rate.............................................23

3.7

Central Heating................................................23

3.8

Temperature Controls......................................23

3.9

Appliance Protection Devices ..........................23

3.10 Re-fit Outer Case.............................................24
3.11 Handing Over to the User ................................24

4.

Servicing...................................................................24

5.

Routine Maintenance...............................................26

5.1 

Remove the White Front Case ........................26

5.2 

Remove Base Panel ........................................26

5.3 

Remove the Air Box Covers ............................26

5.4 

Remove the Fan Assembly..............................26

5.5

Remove the Flue Hood ...................................26

5.6

Remove the Combust. Cham. Front Panel .....26

5.7

To Inspect and Clean the Boiler ......................26

5.8

To Remove the Burner ....................................28

5.9

Gas Pressure Adjustment ...............................28

5.10 The Central Heating Sealed System ...............28
5.11 Other Components ..........................................28

6.

Component Replacement .......................................30

6.1

Central Heating Overheat Thermostat ............31

6.2

Dom. H/Water Limit & Frost Thermostat .........31

6.3

Sensor and Ignition Electrode .........................31

6.4

Sensor and Ignition Leads...............................31

6.5

Spark Ignition Lead .........................................31

6.6 

Thermocouple .................................................31

6.7 

Burner..............................................................32

6.8 

Injectors...........................................................32

6.9 

Gas Valve........................................................32

6.10  Modulating Valve.............................................32
6.11  First Solenoid Valve ........................................32
6.12  Second Solenoid Valve ...................................32
6.13  Case Seal........................................................32
6.14  Central Heating and Boiler Switch...................35
6.15  Electronic Control Boards................................35
6.16  Air Pressure Switch .........................................36
6.17  Fan ..................................................................36
6.18  Fan Seals ........................................................36
6.19  Temperature Sensor D.H.W and C.H..............36
6.20  Pressure Gauge ..............................................36
6.21  Water Flow Switch D.H.W...............................37
6.22  Microswitch (D.H.W Flow Switch) ...................37
6.23  Pump ...............................................................37
6.24  Diverter Valve..................................................38
6.25  Expansion Vessel D.H.W ................................39
6.26  Expansion Vessel C.H.....................................39
6.27  Heat Exchanger...............................................40
6.28  Automatic Air Vent...........................................40
6.29  Pressure Relief Valve......................................40
6.30  Water Pressure Switch ....................................41
6.31  Transformer Assembly ....................................41
6.32  Sight Glass with Securing Frame ....................41

7.

Schematic Diagrams - Permanent Pilot............. 42/45

8.

Schematic Diagrams - Electronic....................... 46/49

9.  Short List of Spares............................................. 50/51

GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1994. (As Amended)

The appliance must be installed and serviced by a competent person, in accordance with the above Regulations.

In the UK 'Corgi' Registered Installers (including the Regions of British Gas) undertake the 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.