Potterton 80e, Installation & Service Instructions Manual

Page 1: ...cordance with the above regulations Failure to install appliances correctly could lead to prosecution Installation must be in accordance with these instructions and the rules in force in the country of destination The polythene bags used for packaging are a potential hazard to babies and young children and MUST BE DISPOSED OF IMMEDIATELY LEAVE THESE INSTRUCTIONS WITH THE USER FOR USE ON FUTURE CAL...

Page 2: ...omponents 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 Cen...

Page 3: ...ctrical Supply 230V 50Hz Fuse Rating External 3A Packed Weight 62 5kg 137lbs Water Content C H 1 9 litres Gas Supply Connection 1 2 B S P F Gas Cock Inlet Connection D H W 15mm Compression Isolating Valve Outlet Connection D H W 15mm Copper Pipe Flow Connection C H 22mm Compression Isolating Valve Return Connection C H 22mm Compression Isolating Valve Safety Discharge Pipe 15mm Copper Pipe C H Sea...

Page 4: ...ms with small terminals simplify siting and installation They are supplied fully tested and assembled with a circulating pump diverter valve pressure gauge pressure relief valve and expansion vessels The appliances have two completely separate heating systems embedded into a copper heat exchanger Both systems are completely independent A central heating switch controls the choice of service betwee...

Page 5: ...Optional Extras Page 5 ...

Page 6: ...Optional Extras Page 6 Installation instructions included as necessary with each kit ...

Page 7: ...Optional Extras Page 7 Installation instructions included as necessary with each kit ...

Page 8: ...ultation with the Local Gas Region A gas meter can only be connected by the Local Gas Region or by a Local Gas Region Contractor An existing meter should be checked preferably by the Gas Region to ensure the meter is adequate to deal with the rate of gas supply required Installation pipes should be fitted in accordance with BS 6891 Pipework from the meter to the combination boiler must be of an ad...

Page 9: ...in Timber Frame Housing Reference DM2 If in doubt advice must be sought from the Local Gas Region of British Gas The combination boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current I E E Wiring Regulations and in Scotland the electrical provisions of the Building Regulations applicable in Scotland with respect to the insta...

Page 10: ... is also available for flue heights up to 8025mm when used in conjunction with one metre twin tube extension kits A Pitched Roof Flashing kit and Flat Roof Flashing kit are available for use with the vertical flue systems 135 Off set kits are available for both concentric and twin tube The siting of the flue terminal through a roof is shown in Fig 6 c Only the above flue systems should be used wit...

Page 11: ...ral heating output from the boiler can easily be downrated if a lower temperature drop across the system is prefered If the central heating system requires an increased pump head a second circulating pump should be installed The pump must be sited on the return to the boiler and electrically connected using a proprietry relay i e Drayton RB1 see Section 2 6 The domestic hot water system must be in...

Page 12: ......

Page 13: ...The hose should be disconnected after filling Where the mains pressure is excessive a pressure reducing valve shall be used to make filling easier The following fittings shall form a permanent part of the system and shall be fitted in the order stated a A stop valve complying with the requirements of BS 1010 Part 2 the temporary hose from the draw off tap shall be connected to this fitting b Doubl...

Page 14: ... F can be used without increasing radiator sizes From this intersection point draw a horizontal line so that it intersects the PUMP CURVE From this intersection draw a vertical line upwards The AVAILABLE PUMP HEAD can now be read from the horizontal scale and the corresponding FLOW RATE from the vertical scale in the centre of the chart The system must be designed so that its hydraulic resistance ...

Page 15: ...y supply must provide means of completely isolating the electrical supply to the combination boiler and its ancillary controls The appliance is designed to be the wiring centre for the installation therefore no additional live supplies are required from either timers or room thermostats Isolation is preferably by the use of a fused three pin plug and unswitched shuttered socket outlet both complyi...

Page 16: ...he top clearance should be a minimum of 160mm but 300mm is preferred to allow removal of the central heating expansion vessel without removing the appliance from the wall if replacement is required Bottom Clearance A bottom clearance of 220mm is required between the appliance and any surface Frontal Clearance A minimum of 500mm is required in front of the appliance for access during servicing the ...

Page 17: ...e panel pull the base of the panel forward approx 50mm and lift off the supporting top hooks Fig 15 c Remove the base cover by removing the two fixing screws and push the cover towards the rear to release d Each side panel can now be individually removed by removing the two front fixing screws loosening the lower rear fixing screw and sliding the panel upwards to unhook from the upper rear fixing ...

Page 18: ...lower flow is required there is a throttle valve located below the D H W mini expansion vessel SHOWERS If a shower control is to be supplied from the Combination unit it should be of the type which incorporates a pressure balancing valve i e MIRA 415 EQUAMATIC If the shower control is existing and is of a mechanical type it may be necessary to fit a drop tight pressure reducing valve to the mains ...

Page 19: ... 18 Note Ensure that all cables pass through the wiring panel bush s and are securely fixed by the cable clamp s If a room thermostat is to be fitted remove the Red link wire between terminals 3 and 4 and discard prior to wiring in the thermostat If no room thermostat is to be fitted retain link wire If a programmable room thermostat is to be used it must be fitted in place of the external timer a...

Page 20: ...rect polarity earth continuity and resistance to earth If a fault has occurred on the appliance the fault finding procedure should be followed See pages 39 48 3 2 Gas Installation The whole of the gas installation including the meter should be inspected and tested for soundness and purged in accordance with the recommendations of BS 6891 Purging air from the gas line may be carried out by loosenin...

Page 21: ... boiler switch is set to Stand by and the central heating switch is set to the Off position Mid position f Check that the Hot Water and Central Heating temperature controls on the control panel are set to their lowest setting g Check the Gas service cock is On h Check that the boiler isolating valves and radiator valves are open i Check that any time controls are in an On condition and any room th...

Page 22: ... stated on the data plate without affecting the D H W output If adjustment is required see Section 3 4 Gas Pressure Adjustment 3 4 Gas Pressure Adjustment Note The gas pressures are set at the factory with central heating output set at maximum and should not require further adjustment If gas pressure readings are being obtained which differ from that stated in Table 4 check the inlet pressure usin...

Page 23: ...rmance can be assessed by placing a suitable sampling probe through the access hole in the inner casing door whilst the appliance is running Typical figures based on a 500mm flue length with the boiler operating at maximum output are CO 0 002 0 005 CO2 4 5 5 0 Replace the screw in access hole after test ...

Page 24: ...ut down or Lockout On the 100 model with permanent pilot this will be indicated by the pilot being extinguished To restart the appliance follow the lighting instructions on the boiler facia label or as shown in Section 3 3 On the 100e model electronic this will be indicated by the lockout light being illuminated To Reset the appliance press the RESET button on the front panel and hold in that posi...

Page 25: ...nded periods the boiler will be protected even when the switch is set to Off Mid position 4 Servicing Page 24 To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage but in general once per year should be adeq...

Page 26: ...MPORTANT After completing any servicing or replacement of a gas carrying component it is essential that a test for gas soundness is made and functional checks of controls operation carried out Additional Information To ensure correct performance and that an adequate seal is obtained around the flue hood and heat exchanger various seals have been added to the appliance Please bear in mind when serv...

Page 27: ...at exchanger is now exposed 5 7 To Inspect and Clean the Boiler Fig 24 a Inspect the heat exchanger for any blockage Deposits of any material should be brushed away using a soft brush Note Do not use brushes with metallic bristles b Examine internal pipe work connections and automatic air vent for any water leaks Rectify if necessary c Examine the combustion chamber insulating material and renew i...

Page 28: ...Routine Maintenance Page 27 ...

Page 29: ...ng pressure of the system when cold If the pressure gauge needle indicates a lower pressure than the red marker or the Low System Pressure light is illuminated the system has lost pressure and should be re pressurised The correct procedures are shown in the installations section See permissible methods of filling Page 12 5 11 Other Components No further servicing is required on any other appliance...

Page 30: ...Routine Maintenance Page 29 ...

Page 31: ... The appliance gas supply should be isolated at the boiler gas service cock one quarter turn of square spindle The Central Heating and Domestic Hot Water circuits can similarly be isolated at their respective valves A drain point is provided in the appliance heating circuit under the pump manifold and the cold water inlet isolating valve also incorporates a drain screw Use a suitable tube when dra...

Page 32: ...air box cover See 5 1 to 5 3 in Routine Maintenance b Lower control panel one screw c Note run of lead Remove lead ends from electrode and Full Sequence Control Board Pass lead through the silicone grommet d Fit new lead in correct position e Re assemble in reverse order Ensure the silicone grommet is correctly fitted and not damaged Replace if necessary 6 5 Spark Ignition Lead Permanent Pilot ver...

Page 33: ...gas supply tube to the new valve Replace the O rings if necessary On Permanent pilot versions refit the interrupter and the valve knob extension i Re assemble in reverse order ensuring that the black and red wires low voltage are connected to the modulator valve Fig 28 or 29 Polarity is not important 6 10 Modulating Valve a Remove the white front case See 5 1 in Routine Maintenance b Disconnect th...

Page 34: ...Component Replacement Page 33 ...

Page 35: ...Component Replacement Page 34 ...

Page 36: ...e white front case and base panel See 5 1 5 2 in Routine Maintenance i USER DISPLAY BOARD a Remove the thermostat knobs and reset button b Undo the fixing screw retaining the facia panel and swing the panel downwards c Remove the plug connector s from the rear of the board and undo the four securing screws d Replace board and re assemble in reverse order ii MODULATION CONTROL BOARD Note The board ...

Page 37: ...ont case and base panel See 5 1 5 2 in Routine Maintenance b For D H W sensor lower the control panel assembly by undoing the securing screw at the top right hand side of the control panel c Before removing the hot water or central heating sensor first close the isolating valves for the circuit involved and drain the appliance For C H with both 22mm isolating valves closed reduce the system pressu...

Page 38: ...d position the switch as dimensioned in Fig 32 e Re assemble in reverse order Ensure the wires are connected correctly as shown in Fig 32 6 23 Pump Fig 26 For ease of replacement it is advisable to fit a new motor head assembly to the existing pump housing This will prevent excess dismantling and save time as the motor assembly may well need to be removed from the new pump to correctly position th...

Page 39: ...sing a twisting action and carefully remove the head Note the position of the loose brass cylinder on the wax capsule push rod and transfer onto new head assembly g Fit new wax capsule head re assemble in reverse order Replace pipe seals is necessary ii Complete valve replacement a Remove the white front case and base panel See 5 1 5 2 in Routine Maintenance b Lower the control panel assembly by u...

Page 40: ...ve the flue elbow 4 screws f Remove the top expansion vessel securing bracket assembly four screws and slide the vessel complete with flexible pipe upwards out of the appliance g Remove the flexible pipe from the old vessel and refit using a new sealing washer to the new expansion vessel at this stage the pre charge pressure can be easily checked and corrected if necessary The pressure should be a...

Page 41: ...heck the joints for leaks 6 28 Automatic Air Vent Fig 35 a Remove the white front case base panel and white left hand side panel See 5 1 5 2 5 3 in Routine Maintenance b Close the central heating isolating valves reduce the system pressure by opening the pressure relief valve then part drain the water from the boiler by opening the bleed valve on the right hand side of the diverter valve c Using a...

Page 42: ...ee terminals do not use the terminal insulated by sleeving The wires must be connected to the terminals on the switch body marked 1 2 Normally Closed g Open the isolating valves Re charge the system as described in section 1 6 and check for leaks 6 31 Transformer Assembly Fig 38 a Remove the white front case and base panel See 5 1 5 2 in Routine Maintenance b Lower the control panel assembly by un...

Page 43: ...7 1 Control Flow Sequence Permanent Pilot Page 42 ...

Page 44: ...7 2 Functional Flow Permanent Pilot Page 43 ...

Page 45: ...7 3 Fault Finding Permanent Pilot Page 44 ...

Page 46: ...7 4 Electrical Diagram Permanent Pilot Page 45 ...

Page 47: ...8 1 Control Flow Sequence Electronic Page 46 ...

Page 48: ...8 2 Functional Flow Electronic Page 47 ...

Page 49: ...8 3 Fault Finding Electronic Page 48 ...

Page 50: ...8 4 Electrical Diagram Electronic Page 49 ...

Page 51: ...9 Short List of Spares Page 50 s ...

Page 52: ...88 379 349 16 Pressure Gauge 1 929644 289 531 17 Burner Injector Polidoro 1 17mm 16 929529 379 347 18 Air Flow Switch Honeywell C6065A1093 1 642212 379 350 19 Diverter Valve Assembly Complete 1 929651 289 718 20 Wax Capsule Assembly 1 929803 289 741 21 D H W Flow Switch 1 929673 289 724 22 D H W Thermostat Flow Limiter Assembly 100 100e 1 929670 289 737 23 Fan Assembly 1 929502 379 343 24 Piezo Ig...