Potterton Isis HE, Installation, Operation & Maintenance Manual

Page 1: ...MAY 2004 ...

Page 2: ...the Casing 15 Fig 7 Boiler Insulation 15 Fig 8 Fitting Locknuts to Studs 15 Fig 9 Front Panel Fixing 15 Fig 10 Door Fixing 16 Fig 11 Door Micro Switch 16 Fig 12 Firing Door Casing Insulation 16 Fig 13 Control Panel 17 Fig 14 Rear Casing 17 Fig 15 Boiler Side Rails 17 Fig 16 Boiler Side Panel Fixing 17 Fig 17 Side Front Panel Fixing 18 Fitting the Inserts 18 Insert Removal 18 Boiler Tool Storage 18...

Page 3: ...amber Data No of Sections 6 7 8 9 10 11 12 13 14 15 Mean Diameter mm 635 Cross Sectional Area m 0 343 Length mm 920 1100 1280 1460 1640 1820 2000 2180 2360 2540 Volume m3 0 291 0 349 0 407 0 465 0 522 0 581 0 639 0 697 0 754 0 811 Surface Area m2 2 15 2 51 2 86 3 22 3 58 3 94 4 3 4 65 5 01 5 38 Resistance mm 38 55 73 57 71 67 73 57 100 Flue Gas Temperature Gross C 180 Efficiency Net Gross 90 82 2 ...

Page 4: ...nts 0 4 mm ALL MODELS 5 High Level Natural Ventilation to BS 6644 cm2 1342 1550 1742 1973 2225 2439 2673 2878 3070 3350 5 Low Ventilation Natural Ventilation to BS 6644 cm 2 2684 3101 3485 3946 4451 4851 5346 5757 6141 6700 6 Mechanical Inlet to BS 6644 m3 sec 0 482 0 566 0 644 0 735 0 836 0 922 1 02 1 097 1 175 1 286 7 Water Connection Size See Fig 3 4 BSP 3 4 8 Water Flow at 11 C t lit sec 9 5 1...

Page 5: ... respectively on gas and oil 5 NATURAL VENTILATION The sizes indicated are free grille areas and are based on a single boiler installation 6 MECHANICAL VENTILATION The volume given is for a single boiler installation 7 WATER CONNECTION SIZES The boiler connections are flanged with 3 BSP screwed counter flanges provided For further details on water connections see Fig 3 and Fig 4 3 4 extension turr...

Page 6: ...e Potterton Isis burner data sheets NB There is a separate data sheet for each burner type eg NuWay Riello EOGB The burner should be fitted in accordance with the instructions in Section 4 The burner unit should be commissioned in accordance with the manufacturers instructions and Potterton burner card supplied with the burner to obtain the combustion figures detailed Burner commissioning requires...

Page 7: ...Fig 3 Boiler Water Connections 6 7 Section Fig 4 Boiler Water Connections 8 15 Section A B Interconnected Flow C Return 3 to 4 Extension Turret A Flow B Return A B Interconnected Flow C Return A 3 B 3 C 3 A 3 B 3 A B 2 5 A 3 B 4 A B 3 Flow 4 C 4 A 3 B 4 A B 4 Flow 4 C 4 Flow Return Return Flow Return Return ...

Page 8: ...s constructed with BS1452 Grade220 cast iron heat exchanger constructed in accordance with EN303 1 The boiler package meets Gas and Oil requirements of M E3 and burners EN767 The waterway sections are joined with O rings and secured with tie rods with the final sealing of the combustion chamber being made during assembly with boiler cement and silicone rubber The boilers are supplied unassembled a...

Page 9: ...l and Industrial gas Fired Boilers and Air Heaters IGE UP 1 Soundness Testing Purging Procedure for Non domestic Installations IGE UP 2 Gas Installation Pipework Boosters Compressors for Industrial Commercial Premises BS EN 303 1 303 In the event of a gas booster being necessary refer to IM 16 Guidance Notes on the Installation of Gas Pipework Boosters and Compressors in Customers Premises and the...

Page 10: ...n sizes are given in Table 3 these sizes refer to the boiler flue connection spigot The actual size of the flue system will depend on individual site applications Below are general considerations on sizing flue systems Horizontal Flue Runs Horizontal flue runs are not recommended particularly over 3m in length where these are unavoidable advice should be sought from a flue system specialist Common...

Page 11: ...POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 3 INSTALLATION OPERATION MAINTENANCE MANUAL PAGE 9 ISIS HE ...

Page 12: ...oilers This can normally be achieved by cutting open a failed boiler section and examination for system debris or contamination Lime scale is a positive indicator of continuous system water make up due to water loss Evidence of magnetite black sludge in the system and the formation of gas in radiators causing air locking is a positive indicator of corrosion Where an old system shows evidence of co...

Page 13: ... work are adapted for all boiler maintenance and repair work undertaken on site 2 The work undertaken does not affect the electrical safety of the appliance In particular the earth connected to the buildings fixed electrical installation In the case of 1 above electrical work should only be undertaken once the boiler has been isolated from the electricity supply and confirmed electrically dead If ...

Page 14: ... advice Potterton Commercial Customer Erection Assembly Check List The items listed below have been put together as a guide to what actions should be completed before the erection assembly of a boiler takes place I Site access available for persons carrying out the proposed work II Site managers personnel aware that work will be taking place III Risk assessments carried out on possible risks that ...

Page 15: ...y for the boiler cement as some cartridges may contain a certain percentage of water which should be safely drained off before use The sealants and sealant gun which are supplied with the boiler are classified as consumables In addition to this items standard boiler erection tools will be required These should include a crowbar heavy duty adjustable wrench and a jack for raising the firing door Er...

Page 16: ...ytande Pt No 922111 No Rqd Silicone Primer Pt No 922119 No Rqd 6 440 1 4 1 5 9 2 7 516 1 5 1 5 11 2 8 586 1 6 1 6 12 2 9 670 1 7 1 7 13 3 10 762 1 8 1 8 15 3 11 840 1 9 1 9 16 3 12 925 1 10 1 10 18 3 13 1000 1 11 1 10 19 3 14 1070 1 12 1 11 20 4 15 1172 1 13 1 12 21 4 Weights are approximate Fig 5 Waterway Sealing Details SMOOTH SEALANT INTO JOINTS AFTER TIGHTENING UP SECTIONS SPRAY PRIMER ON ALL ...

Page 17: ... in position Ensure that the boiler remains in alignment during assembly of the waterways 12 Prepare the sealing grooves and O ring guides of the forward face of the intermediate section assembled in operation 8 and the rear face of the next intermediate section to be fitted Proceed as previously described until all intermediate waterway sections and the front waterway section have been assembled ...

Page 18: ...it casing panels as detailed in the paragraphs 1 12 below the flue spigot as paragraph 19 and the burner as detailed under relevant section However the remaining casing and insulation can if required be fitted after construction has ceased in the boiler house to minimise damage to the casing Fig 7 Boiler Insulation 1 Fit the insulation strip to the front section as shown in Fig 7 and secure in pos...

Page 19: ...ts are fully tightened and forming an adequate seal between the door and combustion chamber 5 Fit the door micro switch using the bracket provided Close the door and adjust the switch so that the plunger is depressed by the front panel when the door is closed Slots in the bracket facilitates adjustment see Fig 11 6 Fit the firing door insulation panel see Fig 12 7 Fit the door casing using the fou...

Page 20: ...ction boilers these are omitted On larger boilers there are eight rails provided two for each corner which should be drilled and fixed together to obtain the correct overall case dimension see Table 1 Fig 15 Boiler Side Rails 15 Mount the side casing panels starting from the rear of the boiler Larger boilers will have additional side panels see parts list It will be necessary to drill fixing holes...

Page 21: ...moval ring and withdrawing Boiler Tool Storage Following completion of boiler assembly the cleaning tools insert removal tool and door access socket and T bar should be left in a safe and secure position within the boiler room It is recommended that a tool rack is incorporated within the boiler house for this purpose Fitting the Burner 1 Check that the burner which has been supplied is the correct...

Page 22: ... 8 9 10 11 12 13 14 15 L Overall Length 945 1125 1315 1315 1665 1665 2025 2025 2385 2385 D Major Diameter 60 60 55 55 60 60 55 55 50 50 d Minor Diameter 60 60 50 50 54 54 50 50 44 5 44 5 A Major Diameter Length 455 635 615 615 1165 1165 1325 1325 1685 1685 B Minor Diameter Length 490 490 700 700 500 500 700 700 700 700 Fig 18 Insert Position Fig 19 Insert Position D d B A L INSERT LEGS FLUEWAY INS...

Page 23: ... by up to 10 Not only does this waste fuel but the higher flue gas temperatures that result will increase the thermal stress within the boiler and may lead to joint leakage or in extreme cases section failure Natural gas manufactured gas LPG Fired Boilers We recommend brushing out of the combustion chamber and flueways and the removal of the rear clean out covers to check for deposits in the flue ...

Page 24: ...etails on water circulation systems 5 Ventilation is adequate and in the case of mechanical ventilation systems operation of the boiler is inhibited unless the ventilation fan is proved 6 On mechanically assisted flue systems the operation of the boiler plant should be inhibited unless the mechanical flue system is operational and flow proved 7 The safety valve should be checked to ensure that it ...

Page 25: ...ce notes on system fault finding Overheat Operation a The boiler system pump is adequate for the duty b Operation of flow reducing devices ie TRV s compensated mixing valves etc do not reduce the water flow rate through the boiler below the minimum flow rates c Pump overrun is incorporated to dissipate residual heat from the boiler on system shut down d The operation of boiler back end valves inco...

Page 26: ... Low Interlock Control Interlock Remote Burner Lockout Signal Incoming Supplies 415V 50Hz 3Ph N A J K G L H M D C B P E F N LIMIT INDICATOR High Low Stat Control Stat Limit Stat Manual Reset 2 0 2 1 4 11 10 9 8 7 6 P 4 1 2 1 07 17 14 13 20 16 15 10 5 4 3 2 1 18 19 AMPHENOL SOCKET Denotes Site Wiring Black White Thin Purple Orange Dark Blue Thin Grey Red Thin Light Blue Thin White Red Thick Green Y...

Page 27: ...pply Pump No C Nc Auxillary Contact on boiler time control etc Pipe Thermostat Set 55o L 4 WAY VOLT FREE CONNECTOR BOX R2 N 240 V AC NO 14 NC 12 COM 11 R1 N 240 V AC NO 14 NC 12 COM 11 R4 N 240 V AC NO 14 NC 12 COM 11 R3 N 240 V AC NO 14 NC 12 COM 11 11 9 6 4 N VOLT FREE CONTACTS R1 BURNER LOCKOUT INDICATION R2 1ST STAGE RUN INDICATION R3 2 ND STAGE RUN INDICATION R4 OVERHEAT INDICATION N NEUTRAL ...

Page 28: ...OT SHOWN See Table Below Boiler Body Insulation 0 6m Roll NOT SHOWN See Table Below Front Casing Insulation Strip NOT SHOWN 922217 2 Insulation Sealing Tape NOT SHOWN 922214 2 Cafco Blaze Burner Sealing Compound NOT SHOWN 923010POT 2 bags Casing Pack Details Boiler Sections SIDE PANEL No Off x part No x length TOP REAR INTERMEDIATE PANEL No Off x part No x Length SUPPORT RAIL No Off x Part No x Le...

Page 29: ...3 1 24 Coupling Nut 922184POT 1 25 Micro Switch Bracket Fixing Screw M6 x 12mm 922005 2 26 Clean Out Door 3 Insulation Block 922125 1 Screws Hex M6 x 30 mm COM920060 1 27 Locking Handle excluding item 28 922015 6 28 M10 x 50mm Stud 922185 6 29 3 to 4 Extension Turret 922126 2 30 4 Counter Flange Table D 650115 2 31 4 Gasket 354697 2 32 M16 x 50mm Bolt including Nut 617610 8 33 Flange for Thermosta...

Page 30: ...crew Burner NOT SHOWN 633301 4 75 Optional Special Flue Box 6 9 Section 922163 1 76 Amphenol Socket NOT SHOWN 922234 1 77 High Limit Thermostat 922139 1 78 Control Thermostat 922138 1 79 High Low Thermostat 922138 1 80 Boiler Temperature Gauge 922144POT 1 81 Boiler Altitude Gauge 922158 1 82 Triple Thermostat Pocket 922142 1 83 Single Thermostat Pocket 922143 1 84 Pressure Gauge Non Return Valve 9...

Page 31: ...PAGE 28 ISIS HE Isis Casing Details Adaptor Plate Thermometer Pocket Thermostat Pocket C 83 82 D 58 66 33 37 38 A B FIRING DOOR T S R 35 38 61 62 59 A REAR PANELS 26 27 28 39 44 65 L K J H TOP PANELS W Q V M X D P N 9 10 11 12 60 34 37 38 G E F SIDE PANELS C 29 30 31 32 37 38 75 67 69 D 22 24 ...

Page 32: ...POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 7 INSTALLATION OPERATION MAINTENANCE MANUAL PAGE 29 ISIS HE Isis Boiler ...

Page 33: ... 11 Flue Draught mmwg 5 12 Inlet Gas Pressure high fire If multi boiler installation inlet gas pressure all boilers high fire mmwg 5 13 Combustion Chamber Resistance mmwg 5 14 Burner Fan Static Pressure mmwg NOTE Normally 5 13 and 5 14 only recorded when tappings provided Position of measurement to be in accordance with boiler and or burner manufacturers instructions GAS FIRED INSTALLATIONS ONLY O...

Page 34: ...and diameter of connection to boiler TYPE DIAMETER mm Where appropriate and for multi boiler installations sketch details of flue system showing length of runs and diameters Conventional Fan Assisted Flue Dilution 7 14 Approximate overall height m Is the fan interlocked with the boiler YES NO 7 15 Are flue dampers fitted YES NO If so interlocked YES NO 7 16 Fan assisted ventilation YES NO 7 17 Any...

Page 35: ... g 0 0394 in w g 1 mm w g 9 8 Pa LENGTH 1m 1000mm 1 inch 25 4mm 1 ft 0 3048 m 1 yard 0 9144 m 1 mile 1 609 km 1 mm 0 03937 in 1 m 3 281 ft 1 m 1 094 yard 1 km 0 6214 mile VOLUME 1 ft3 0 02832 m3 1 ft3 28 32 litre 1 m3 35 3147 ft3 1 litre 0 03531 ft3 AREA 1 in2 645 2 mm2 1 in2 6 452 cm2 1 ft2 929 cm2 1 ft2 0 0929 m2 1 mm2 0 00155 in2 1 cm2 0 155 in2 1 m2 1550 in2 1 m2 10 76 ft2 FLOW RATE 1 kg sec 1...

Page 36: ...072466 Fax 01924 420276 Our service offices offer a wide range of specialised services including Boiler Site Assembly Burner Commissioning for all Fuels Boiler Maintenance Maintenance Contracts Breakdown Repair Services Boiler Dismantling Re Jointing Burner Boiler Replacement Oil Gas Conversions System Conditioning Water Treatment Descaling Packaged Units Potterton Commercial spares are available ...