Potterton Statesman 45/50, Installation & Service Instructions Manual

Page 1: ...balanced flue This boiler is for use with Kerosine or Gas Oil and for use in GB IE About Safety Installation must be in accordance with the Installation Service Instructions and the rules in force Leave these instructions with the user for use on future calls Statesman 45 50 50 70 70 90 90 110 System Flowsure Flowsure Installation Service Instructions ...

Page 2: ...s 40 Thermostats Statesman System 41 Limit Thermostat 41 Boiler ControlThermostat 41 Thermostats Flowsure Flowsure 42 Boiler ControlThermostat 42 LimitThermostat 42 Pump OverrunThermostat 42 Tank LimitThermostat 42 DHW OverheatThermostat 42 HeatstoreThermostat 42 Automatic AirVent 42 Pressure ReliefValve 43 Circulating Pump 43 ExpansionVessel 43 Pressure Temperature Gauge 43 DiverterValve 43 Flow ...

Page 3: ...a doctor DO NOT INDUCE VOMITING NEVER APPLY heat to a fuel tank pipework or container AVOID INHALING fuel vapour it can make you light headed and seriously impair your judgement ALWAYS STORE fuels in a properly constructed and labelled tank If there is a Fuel Spillage IMMEDIATELY STOP SWITCH OFF all electrical and other ignition risks REMOVE all contaminated clothing to safeguard yourself against ...

Page 4: ...ood hygiene practices wash hands before touching eyes consuming food drinking or using the toilet First Aid Medical attention must be sought following eye contact or prolonged reddening of the skin Flue Gas Sampling Point To aid commissioning a flue gas sampling point is built into the heat exchanger front access door If this door is removed make sure that when re fitted the sampling point is at t...

Page 5: ...nlet Knock out Holes For Cables And Fuel Pipes Side Cover Burner Air Inlet Boiler Shell Burner Oil Feed Pipe Statesman Top Casing Side Flue Knockout Thermostat Pocket Front Access Door Burner Lead Flue Gas Sampling Viewing Window Front Cover Burner Lockout Reset Button Control Thermostat Indicator Lights Programmer Optional ST00205A ...

Page 6: ...tank on Flowsure to the heat exchanger whenever there is a flow of domestic water through a hot water tap The domestic water thereby extracts the heat from the plate heat exchanger giving mains pressure domestic hot water The domestic hot water temperature can be increased by reducing the water flow rate at the tap Flowsure or adjusting the hot water mixing valve to a higher setting Flowsure Pump ...

Page 7: ...essel Connection Boiler Drain Valve Burner Air Inlet Pipe Burner Lockout Reset Button Burner Oil Feed Pipe Knock out Blanks For Cables And Fuel Pipes Thermostat Pocket Programmer Optional Expansion Vessel Cradle Pressure and Temperature Gauge Expansion Vessel Connection Pipe Combustion Chamber Viewing Window Combustion Chamber Access Panel Flow 22mm Return 1 B S P Left Right hand Statesman Convent...

Page 8: ...tat Sleeve Plate Heat Exchanger D H W Overheat Thermostat 3 bar Expansion Vessel Expansion Vessel Valve Expansion Vessel Connection Pipe Expansion Vessel Support Bracket 3 Way Diverter Valve C Heating Return 1 B S P C Heating Return 1 B S P Boiler limit Stat Temp Guage Bulb Pocket Expansion Vessel Connection Boiler Drain Valve Double Check Valve System Fill Flexible Hose DO NOT use as a permanent ...

Page 9: ...ual Air Vent Certain Items Removed For Clarity Conventional Flue Boiler limit Stat Temp Guage Bulb Pocket Plate Heat Exchanger Plate Heat Exchanger Expansion Vessel Connection Valve Expansion Vessel Connection Pipe Expansion Vessel Support Bracket Expansion Vessel Expansion Vessel Valve 3 Way Diverter Valve Double Check Valve C Heating Return 1 B S P System Fill Flexible Hose DO NOT use as a perma...

Page 10: ...br b g y gy gy br br br r bl bl b br b br b b b br Boiler Control Panel Wiring Diagram Statesman N E L Live Main Supply Connection L L E E N N S L S L Neutral Pump Tray Assembly Link to be replaced with room thermostat N Boiler Control Panel Wiring Diagram Statesman Earth N L N L N L N N E E L L N N L N L N L Terminal Block Terminal Block Overheat Burner Lockout Mains On N E L Burner Socket Main S...

Page 11: ... o Orange p Pink bl Black b g y br r b b g y bl br br Control Panel Wiring Diagram N E L Live Main Supply Connection L N S L S L Neutral Earth 11 1 31 11 A2 10 A1 2 14 3 34 9 12 4 32 8 22 5 24 7 21 6 Flow Switch Diverter Valve Pump Tray Assembly L L 1 1 E E N N L L S L S L L L L N E Relay br br v o b g y gy gy y o r v o br bl bl o r br br br br br b b b bl bl b b p b g y b b br p gy w g y g y w gy...

Page 12: ... 2 14 3 34 9 12 4 32 8 22 5 24 7 21 6 Flow Switch Tank Thermostat Diverter Valve Pump Tray Assembly L L 1 1 E E N N L L S L S L L L L N E Relay 1 2 br br v v o g y gy o r v o br bl bl o r br br br br br b b b bl bl b b p b g y b b br p w g y g y w gy gy bl br br r bl gy gy 0 47 UF Capacitor LINK to be replaced with room thermostat L N CH ON HW ON 1 1 1b 1a 1a o Electro mech Clock 3 Position Switch...

Page 13: ...i MinimumStaticHead 5 0 ft Water 3 0 p s i MaximumOperatingTemperature 82 C 180 F MinimumOperatingTemperature 55 C 131 F Maximum Boiler Operating Pressure 3 Bar 43 5 p s i Class 2 Conventional Flue Draught at Boiler FlueOutlet 0 035 w g 8 75 N m Minimum 0 16 w g 40 0 N m Maximum LimitThermostatSetting 110 C 230 F Manual Reset MaximumCasingPanelTemperature Less Than 35 C Above Room Temperature Maxi...

Page 14: ... ltr Imp BSP mm mm mm mm A B C D E F G H J K 45 50 50 70 850 390 565 100 100 569 97 59 1 B S P 1 B S P 105 18 2 4 0 610 12 6 25 70 90 850 490 565 100 125 569 97 59 1 B S P 1 B S P 122 20 5 4 5 610 12 6 25 System 850 490 565 100 125 97 59 1 B S P 22mm 130 20 5 4 5 610 12 6 25 Flowsure 850 490 565 100 125 97 59 1 B S P 22mm 15mm 15mm 15mm 145 20 5 4 5 610 12 6 25 Flowsure 850 590 565 100 125 97 59 1...

Page 15: ...Kits 7 8 Kits 5 6 if required Kits 5 6 if required Kits 5 6 if required Kit 3 2 150m Min 4 550m Max 20mm Flue Outlet Flue Outlet Flue Outlet C D D K F A Flue Outlet B Boiler Dimensions D Knock out Blanks For Cables And Fuel Pipes G J H 6mm or 25mm Min D Low Level Riser Flue Kits 12 5 6 7 8 For Flue Lengths see tables 990mm Floor Level Kits 7 8 Kit 12 Kits 5 6 if required Flue Kits 1 2 5 6 Suitable...

Page 16: ...equirements of the Building Regulations which are statutory instruments and must be complied with Those for England and Wales are made by the Department of the Environment in London The Building Standards Scotland Regulations are made by the Scottish Office Part F of the Technical Standards to the Regulations covers heat producing appliances and fuel storage The Building Regulations Northern Irela...

Page 17: ...n alternative to a conventional structural chimney for both new and existing buildings A further alternative may be a suitable form of insulated flue pipe normally positioned on a wall outside a building Capacity The chimney or flue must have a cross sectional area throughout its whole length that is at least the area of the flue outlet of the boiler and must be sealed at the boiler with fire clay...

Page 18: ... an appliance is installed to prevent overheating of the appliance and any equipment in and near the appliance c For the satisfactory operation of any draught break or stabilizer which may be fitted Air for Combustion This requirement will be satisfied if the room or space in which the appliance is installed has an opening or duct which is designed to allow the passage of air at all times equivale...

Page 19: ...A Below a gutter or sanitary pipework G From a surface facing the terminal B Horizontal from opening airbrick window etc H Vertical from terminals on the same wall C Above ground or balcony level I Horizontal from terminals on the same wall D Below eaves or balcony J Below an opening airbrick window etc E From an internal or external corner K From vertical sanitary pipework F From a terminal facin...

Page 20: ... is less than 2 metres above ground level balcony or place to which any person has access the terminal must be protected by a guard Flue Guard Part No 26000045 Table Showing the Balanced Flue Clearance Dimensions A B C D E F G H I J K Building Regulations England Wales 1991 600 600 600 Scotland 1990 Balanced 600 600 600 600 600 600 1500 600 600 600 Low Level 1000 600 1000 600 600 600 1500 600 600 ...

Page 21: ...nlikely that a fire will originate from the stored oil and it is the purpose of these recommendations to ensure that a fire which may originate from a building or other external source is not transmitted to the tank contents Adequate safety may be achieved in a number of ways for example a Protecting the tank by a physical barrier or isolating the tank by sufficient space b Enclosing the tank by n...

Page 22: ...is at least equal to the cross sectional area of the fill pipe The vent should normally rise no higher than 600 mm above the top of the tank If the vent pipe rises more than 600 mm above the tank a pressure relief outlet must be provided in the vent at the 600 mm level This is normally a horizontal branch off the vent with a flap at its end This is hinged at the top and fitted so that it is normal...

Page 23: ...e should be located just outside the building at the point where the oil supply line enters It must be activated by a remote sensor located over the burner but in a position clear of any direct radiation or excessive heat Weight operated valves connected to a sensor by wires and pulleys have been used for this purpose It is preferable however to use a valve with a capillary connection between its ...

Page 24: ...structions The pressure relief valve operates at 3 bar 45 lb in Install a pressure relief valve discharge pipe not less than 15 mm diameter and connect to the pressure relief outlet connection using a 15 mm compression fitting The pipe run should be as short as possible run continuously downwards and discharge to the outside of the building where possible over a drain The discharge point must be s...

Page 25: ...he safety valve setting i e 3 65 bar Flowsure and Flowsure The final 600 mm of the mains cold water connection to the boiler should be made in copper tubing to BS 2871 Pt 1 which is recommended for water carrying pipework and must be used for pipework carrying potable water All capillary joints in the D H W pipework must be joined with a lead free solder The boiler is suitable for mains cold water...

Page 26: ...0203A 150mm Pump Twin Pipe Supply System B Max Oil Level 4 metres Above Burner Fire Valve Shut Off Valve Filter Fire Valve Sensor Pump A Single Pipe Supply System Max Head 4m Oil Tank Below or Level with Burner Fire Valve De Aeration Device Isolating Valve Isolating Valve Oil Supply Pipe Filter Fire Valve Sensor Pump Pre Installation Requirements Fig 17 Fig 16 ...

Page 27: ...With Extensions Floor Level 300 Min 950 950 Two Kit 5 Max Wall 103mm Pitched Roof 1000mm to wall or chimney 1000mm to wall or chimney Kit 5 Kit 6 950 300 All Dimensions in mm Kit 4 Kit 4 Kit 9 Flat Roof Flashing Flat Roof 300 Min Roof Height Roof Height High Level Vertical ALL Models Kit Numbers 2 150 2 450 3 400 3 100 2 750 3 700 4 050 2 650 2 950 3 900 3 600 3 250 4 200 4 550 3 4 3 4 6 3 4 5 3 4...

Page 28: ...k the boiler b Select the desired oil feed position and remove the appropriate knockout in the base using a suitable drift c Position boiler d Lift off top casing panel e Carefully remove knockout panel in top casing panel using gentle manipulation f Seal flue pipe to boiler with fire cement g Re fit top casing panel Connecting the Electricity Supply Electrical Connections All electrical wiring mu...

Page 29: ... the control panel This door is designed to come off if any undue pressure is exerted on it when open but can easily be snapped back into place It may however become detached if the appliance has been handled roughly during transit If you find the door is missing when opening the carton check to see if it is amongst the packaging Fuel Pipes Refer to Section 2 Figs 14 16 17 plus Tables 4 and 5 Befo...

Page 30: ...30 Part No 5102478 Installation Commissioning Fig 21 ...

Page 31: ...Part No 5102478 31 Fig 22 Installation Commissioning ...

Page 32: ...32 Part No 5102478 Installation Commissioning Fig 23 ...

Page 33: ...r Brown gy Grey w White y Yellow o Orange p Pink g y Green Yellow L S L S L g y p br b L N N HW ON CH ON b p o w br y 1 2 3 Room Stat Or Programmable Stat Detail With Room Stat Frost Stat Remove Link Boiler Terminal Socket Press Temp Terminal Plug Frost Stat gy Clock Electro mech Only ...

Page 34: ...igh level flow connections and two low level return connections Connect the pipework to the selected connections and blank off the unused ones it is always preferable to connect the flow and return pipe diagonally opposite if at all possible Installation Commissioning System and Flowsure Return connections are provided on each side of the boiler at low level A flow connection is provided at high l...

Page 35: ...Part No 5102478 35 Fig 25 Installation Commissioning ...

Page 36: ... Switch on electricity supply 8 Turn on boiler thermostat The burner will start and should light within 20 seconds If the flame is not established during this time the burner lock out neon will light wait about a minute before pressing the reset button to re commence the lighting sequence Continuous failure to light is almost certainly due to air remaining in the fuel supply 9 Start and stop the b...

Page 37: ...those connections not utilised should be plugged 5 Check that the central heating system has been fully flushed out at installation using a flushing agent If not add a suitable flushing agent to the system and fill the system Then drain the system while hot and immediately refill adding a suitable proprietary corrosion inhibitor such as Fernox The following procedures should be used when filling t...

Page 38: ...essary Remove The Baffle Plate Examine For Damage Replace If Necessary Lift Out The Plate With These Holes Front Access Door Models 50 70 70 90 System Flowsure Flowsure 90 110 has 6 Retarders Baffle Plate For Models 50 70 70 90 System Flowsure Flowsure Clean Combustion Head LD2SH Model Shown Clean Ignition Electrodes Replace Nozzle With One Of Identical Type Disconnect Burner Air Supply Pipe Disco...

Page 39: ...ns Note Check all seals and replace if damaged Remove access door on front of boiler remove retarders and baffle plate not 45 50 noting their positions Brush off all deposits if they show signs of damage replace Examine interior of boiler and if necessary clean Remove any loose debris from the combustion chamber Check the condition of the refractory base and repair any minor cracks with fire cemen...

Page 40: ...ilers only The system water should be topped up as necessary using the filling system provided Filling must be carried out with the system cold so that the pressure can be brought up to the original cold fill reading indicated by the red pointer A careful watch should be kept on the pressure gauge during filling and the mains pressure valve opened slowly Topping up may by arrangement be a part of ...

Page 41: ...at the back On the System boiler disconnect the rear electrical connecter 4 Remove the facia retaining screws at the base of the facia 5 Lift off the facia and disconnect the indicator lights plug 6 Remove the controls assembly securing screws 7 Lift away the controls assembly and un clip both sensors and temperature bulb where fitted from their pockets 8 Remove the retaining screws and split the ...

Page 42: ...ature gauge bulb and limit thermostat sensor from its pocket 3 Remove the locknut securing the thermostat to the controls assembly On re assembly insert the thermostat sensor before the temperature gauge bulb Pump Overrun Thermostat 1 Disconnect the electrical connections 2 Unscrew the two screws securing the thermostat to the controls assembly 3 Remove the clip and withdraw the sensor from its po...

Page 43: ...ve the clip and withdraw the temperature bulb from its pocket 5 Un clip the temperature pressure gauge from its bracket remove gauge carefully withdrawing sensor and bulb capillary tubes through bracket assembly 6 Fit a replacement gauge in the reverse order 7 Open the valves and fill the system as described in Section 2 Pre Installation Requirements Diverter Valve Flowsure Flowsure 1 Drain the bo...

Page 44: ... to the boiler drain the residual water from the hot water pipework Flowsure 1 Remove the electrical spade connectors from the DHW overheat thermostat 2 Remove the flow switch refer to paragraph flow switch replacement in this section 3 Undo nut on cold inlet pipe feed to PHE remove pipe 4 Undo nut on hot water outlet pipe from the PHE remove pipe 5 Slacken the two screws retaining the DHW flow pi...

Page 45: ...Part No 5102478 45 Servicing Maintenance Fig 31 ...

Page 46: ...46 Part No 5102478 Servicing Maintenance Fig 32 ...

Page 47: ...efer to wiring diagram Section 1 12 Burner motor seized Remove and check ease of rotation SYMPTOM CHECK FOR ACTION Boiler Starts No Flame Established No Oil To Burner 1 Oil in the tank Re Fill 2 All valves open from tank to burner Open valves 3 Fire valve correctly set Set as per manufactures instructions 4 Filter blocked Clean and replace elements 5 Air lock in fuel lines Bleed burner 6 Nozzle bl...

Page 48: ...d Replace pump assembly SYMPTOM CHECK FOR ACTION Burner Starts Flame Established But Goes To Lock Out After 15 Seconds 1 Intermittent oil supply Check for dirt in filters or oil in fuel lines 2 If two pipe system that pipework Refer to Table 5 Page 23 is correct 3 Combustion head settings correct Refer to Burner Instructions 4 Photocell not fitted correctly Replace correctly 5 Photocell circuit fa...

Page 49: ...tank correctly 2 Correct nozzle fitted Refer to Burner Instructions and fit correct nozzle 3 Correct oil pressure Refer to Burner Instructions and set correct pressure 4 Correct air settings Do combustion checks and re set 5 Air in fuel lines Bleed air from lines 6 Adequate access for combustion air Refer to Section 2 7 Adequate ventilation Refer to Section 2 8 One sided flame Remove burner clean ...

Page 50: ... temperature necessary replace too high 3 Lack of flow through boiler If possible try circulating pump on higher setting Statesman only 4 Condensation from Chimney Could take place in cold weather due to high efficiency of boiler Check system complies with Standard 5 Noisy Motor Look for signs of oil leaking from pump motor and coupling 6 Pump pressure oscillating Air in oil Dirt in pump regulatin...

Page 51: ...Part No 5102478 51 Notes Notes ...

Page 52: ...essel Flexible Hose E F G 26009158 18 Drain Elbow Boiler E F G 26009109 19 Automatic Air Vent E F G 26009104 20 Pressure Safety Valve E F G 404S601 21 Circulating Pump E F G 405 0317 22 Pressure Temperature Gauge E F G 26009159 23 Diverter Valve F G 26009160 24 Double Check Valve F G 26009144 25 Flow Switch F G 26009166 26 Switch 2 Position F G 26009090 27 Pump Overrun Thermostat F G 26009156 28 P...

Page 53: ...wsure Flowsure 6 90 110 10 11 11 8 2 43 7 9 Not Spared 14 12 13 15 1 3 4 C O M P A C T 3 bar 16 25 25A 17 27 32 40 34 30 31 18 33 41 42 19 35 21 28 29 23 22 24 26 39 37 38 36 20 24 1 2 3 4 5 6 7 8 1 1121 3 1 4 1 5 1 6 1 7 18 1 9 2 0 2 1 22 23 1 0 9 Spare Parts Fig 33 ...

Page 54: ...ontal Low Level Telescopic Short Wall 100 275mm Inner Wall Fasteners Pack 4 wall plugs 4 wood screws KIT 1 Gasket Inner Seal Instructions Outer Seal Dress Plate Horizontal Low Level Telescopic 225 600mm Inner Wall Dress Plate Outer Wall Dress Plate Outer Wall Fasteners Pack 4 wall plugs 4 wood screws KIT 2 ST00139C ...

Page 55: ... Short Wall 100 275mm Kit 7 Horizontal and Vertical Flue Extension 950mm Horizontal and Vertical Flue Extension 300mm Kit 5 Kit 6 Horizontal High Level Telescopic 225 525mm Kit 8 Flashing Flat Roof Kit 9 Low Level Riser Kit 12 Vertical High Level Riser Telescopic Kit 3 Gasket Instructions Fasteners Pack 4 Wall Plugs 4 Wood Screws Inner Seals 1 off Dress Plate Outer Wall Dress Plate Inner Wall Dres...

Page 56: ... Trading Estate Gateshead Tyne Wear NE11 0PG Tel 08706 060 403 Fax 0191 491 7568 Service Enquiries Service Operations Brooks House Coventry Road Warwick CV34 4LL Tel 08706 096 096 Fax 01926 410006 Spares Enquiries Spare parts are available nationwide via the Interpart Stockists network For your local stockist consult Yellow Pages under Central Heating Training Administration National Training Admi...