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Derwent Prestige Plus Installation Guide

1. Return Header 12 Section Return Header 13 Section 1 1 Return Header 14 Section Return Header 15 Section SECTION 6 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 42 DERWENT PRESTIGE PLUS No 5 Return Header 16 Section COMN9270270 Return Header 17 Section COMN91 12060 MS 115 m oe Return Header 22 Section 11 1 6 Manifold Clamp Plate 9 Section Manifold Clamp Plate 10 Section O o _ Manifold Clamp Plate 11 Section __ Manifold Clamp Plate 12 Section __ Manifold Clamp Plate 13 Section Manifold Clamp Plate 14 Section O 11 __ Manifold Clamp Plate 15 Section Manifold Clamp Plate 16 Section Manifold Clamp Plate 17 Section Manifold Clamp Plate 18 Section Manifold Clamp Plate 20 Section Manifold Clamp Plate 22 Section 34 Drain Cock 8 Case Support Bracket 1 0 0 0 0 0 9 Blanking Cap 5 16 Section 1 1 Combustion Chamber Front Plate 10 Section Combustion Chamber Front Plate 11Section NEN NEN ZEN MEN NEN a p p r v 0 MEE MEN NEN Heat Exchanger Rear Plate 13 Section lt Heat Exchanger Rear Plate 14 Section Hea
2. 7 Controls connected operable and calling for heat 8 Sufficient system heating load available to run the boilers in order to complete combustion checks 9 All system pumps operational and available 10 Gas supply completed purged and ready for use 11 Flue system complete adequate and fully functional 12 Permanent ventilation complete and adequate 13 All safety systems fitted and fully operational e g safety valves fuel shut off devices flue fans interlocked etc 14 Safe working environment provided Contravention of Regulations PLEASE NOTE THAT SHOULD ANY ITEMS BE INSTALLED ON A TEMPORARY BASIS EG VENTILATION FLUES ETC THEN THE COMMISSIONING ENGINEER WILL NOT BE ABLE COMMISSION THE BOILER SECTION 4 PAGE 30 COMMISSIONING IMPORTANT The boiler must be commissioned following completion of installation Operation of an uncommissioned appliance may cause injury to personnel and damage to the boiler burner unit and could invalidate the manutacturer s warranties Commissioning should only be carried out by personnel approved and competent to do so This facility is available from Potterton Commercial Service Offices at the addresses as listed on the back page of this manual Before commencing to commission ensure that any cling film is removed from the casing panels and then check the following 1 Electrical supply is of correct voltage and polarity and earthing is available with certific
3. 22 Section 9 Control Panel Housing Front 9 Section __ Control Panel Housing Front 10 Section __ Control Panel Housing Front 11 Section __ Control Panel Housing Front 12 Section __ Control Panel Housing Front 13 Section __ Control Panel Housing Front 14 Section __ Control Panel Housing Front 15 Section __ Control Panel Housing Front 16 Section _ Control Panel Housing Front 17 Section __ Control Panel Housing Front 18 Section _ Control Panel Housing Front 20 Section _ Control Panel Housing Front 22 Section 2 O 9 7 1 1 Side Panel Insulation POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 6 INSTALLATON OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 49 Item Description Quantity Red Casing White Casing Part No Part No No Logo Prestige Plus Badge Not Shown 1 S139057 Si39058 SECTION 6 POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 50 DERWENT PRESTIGE PLUS Fig 37 Flue Box A e 4 Item Description Quantity No Flue Box 9 Section Flue Box 10 Section Flue Box 11 Section Flue Box 12 Section T Flue Box 13 Section Flue Box 14 Section Flue Box 15 Section Flue Box 16 Section O Z o gt Flue Box 17 Section Flue Box 18 Section gt S Fl
4. To set the low fire rate the boiler temperature must be raised above 40 C ie above the minimum operating temperature of the second stage thermostat With a pressure gauge fitted to the burner manifold PTP5 turn the control thermostat down until it clicks Observe that the burner flames have diminished Adjust the low fire rate see page 33 until the burner manifold pressure is 10 6 mbar Operate the burner at high and low fire checking that the burner manifold pressure is correct and that the flame is stable and blue 9 Test the gas connection between the ignition valve and the pilot burner for soundness with a soap solution or other approved method and seal any leakages Switch off the electrical supply and check that the burner has extinguished Remove the pressure gauge from the burner manifold and tighten the pressure test screw on the gas valve 10 Check the reliability of ignition of the boiler by switching the boiler off using the burner on off switch on the boiler control panel After two minutes turn the switch back on The boiler will now relight Check that the pilot has a stable flame and that the main burners light smoothly 11 With the boiler switched on test for soundness on the union which is between the gas train valve and the burner manifold with a soap solution or other approved method and seal any leaks 12 Turn the appliance isolation valve off The main and pilot burners should go off The boiler will a
5. the use of plate heat exchangers New Systems New pipe work systems should be thoroughly flushed with a suitable cleaning agent to remove debris and flux residues before filling The system water should be dosed with a suitable corrosion and lime scale inhibitor System Water Monitoring The system water should be monitored as part of a maintenance programme to ensure the following Raw water make up is not occurring Corrosion and lime scale Inhibitors are still active Water Ph is below Ph 8 5 other wise on systems with aluminium content component failures may occur SEALED SYSTEMS General Potterton Commercial bollers are suitable for use on sealed systems designed in accordance with BS 6644 2005 and BS 6880 Part 2 In addition reference should be made to the Health 8 Safety Executive guidance note PM5 Automatically Controlled Steam 8 Hot Water Boilers Noise Level Derwent Prestige atmospheric boilers are regarded as being commercially guiet ie lt NR63 under typical operating conditions SECTION 4 PAGE 10 BOILER ERECTION A Lifetime Guarantee is available on this boiler when the Potterton Commercial Service Department carries out Erection 8 Commissioning and the system meets with our recommendations Please refer to our Standard Terms and Conditions for further details Risk Assessment Before starting work a risk assessment should be carried out in the boiler house and its access to determine and ens
6. turn clockwise for more pressure or anti clockwise for less pressure on the burner manifold 3 Set the high fire pressure to 16 5 mbar POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS Reduced Rate Setting 1 Reduce the setting of the high low thermostat to minimum so that the boiler goes to low fire 2 Unlock the screw M on the solenoid valve head B and turn to the low rate setting ring N turn clockwise for less pressure and anti clockwise for more pressure on the burner manifold 3 Set the low fire pressure to 10 6 mbar Fig 29 Gas Train 12 22 Section Boilers Governor Setting Screw Protecting Head Security Valve Locking Screw Low Rate Ring Solenoid Valve High Low UZ EI A lonisation Current Check Switch the boiler off at its on off switch and at the main isolator Connect a micrometer into the ionisation cable in between the electrode and the cable Switch on the main isolator and the burner on off switch and after 15 seconds the ignition spark should be heard followed by lighting of the pilot burner The micrometer should read approximately UA at start up without main burner running Switch off the main isolator and the on off switch and remove the micrometer connections Flue Spillage Test With the boiler hot and cold check for spillage of combustion products with a smoke bomb or smoke wand C
7. B at the tie rods is correct b That the manifolds are correctly positioned holes centred in the clamping plates c That the return manifold is at right angles to the sections Tighten all the nuts on the manifolds evenly Fit the temperature monitoring sleeve in the 7 hole H in the section 8 nearest the outlet Fit the drain tap to 34 hole in the return manifold Combustion Chamber Base Plate Put an insulating sealing strip on the bottom right and left edges of the combustion chamber Fig 16 and put an insulation strip on top at the back edge Insert the base plate with the front fold downwards being careful not to damage the seals and ensure a good seal Hydraulic Test of Boiler This is to be carried out on boilers assembled on site or where water manifolds have been disturbed Fit a hydraulic test pump to the return manifold and fit a valve to vent air from the flow connection Fill the boiler with cold water and in accordance with BS 779 1976 pressurise up to 1 5 times the system design pressure ie 7 5 bar maximum and observe for 30 minutes POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS Fig 16 A 27mm silicone rubber bead INSTALLING MULTIPLE UNASSEMBLED BOILERS When two boilers are being built side by side with the minimum practical clearance between them and with one flow connection to the left and the other to the righ
8. PLUS Table 3 Technical Data 9 to 12 Section hn le NC RR OHNE ama w om oe le le ER Fuel Consumption G20 m hr manea m we ez om om Ceata me pom oo Bo RN NE Reese ma Krees eoe INI m 2 ammos m 08 a rona Pue cometon see Um o m 1 Diverter Socket to BS 835 LE NE NE NK REM Flue Draught Requirements 1 4 mm All Sizes mi Level Natural Ventilation to BS 6644 Low Level Natural AE u ON 257 to BS 6644 6 Mechanical Inlet to BS 6644 aan s 0 112 0 126 0 140 0 154 ka Water Connection Size BSP Connection Size 1 MRF INE ii Flow at 11 m At lit sec 2 8 pire ra Flow at 25 C At lit sec 1 25 1 41 1 56 ETS 72 8 Hydraulic Resistance at 11 C At kPa a at 11 CAt kPa 12 81 15 78 18 55 22 2243 Minimum Bore Minimum Bore Safety Valve Size to BS 6644 Nominal Size m prm Partenere 0 0 ima Beton Temporar 6 8 ln x me NE le lm HE NK mr mr ee Poner TO ON CI Pl ana 3 tuso eed For metric to imperial conversions refer to conversion chart inside back cover POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 1 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 3 Table 4 Technical Data 13 to 22 Section Pismo slu le le lu e a Jom we ae ee m Dm ae e E Fuel Consumption G20 m hr 224 238 26 1 28 298 317 354 392 NET rae ze ase pum pom me si om NI 1 E NE NE NEN NECH sm n NR IC a 00000 mo Carver Pare
9. Panel 1 S904712 SA Bolt DZUS 8504314 5 Control Panel Casing 1 0 6 Cable Terminal Suppot o 10 Thermostat 3A 5 10 __ NTC Sensor Not Shown o J 1 POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 6 INSTALLATON OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 53 Fig 39 Gas Valve Item Description Guantity Part No Z O 1 Multiblock Gas Valve 9 11 Section 2 Input Flange and O ring 9 11 Section 1 to 34 Reducer 9 11 Section 4 C1 9A 10 12 3 2 1 Reducer 20 22 Section 14 15 16 17 18 NN uw m NJE 8 187 EE 9 9A 1 zum p 10 EE NEM Elu NE 13 14 E on 16 NEM EM 18 UE COMMISSIONING REPORT ALL BOILER TYPES REPORT SENT TO sli zob bei ee SITE VISIT Italics COMMISSIONING nn Office use Only C Oo M M E R C A L Wood Lane Erdington Birmingham B24 9QP DATE Tel 08706 050607 Fax 08706 001516 SIGNATURE REPORT No SITE ADDRESS COMMISSIONING SITE VISIT DATE BOILER No of Sections Boiler N Position 13 SerialNo 42 Z 1 4 BURNER CONTROLS 2 1 Type Atmospheric Pre Mix Pressure Jet 2 2 lonisation Probe UV Cell Thermocouple Make Model Make Model Control Box Type 2 7 Electrical Supp
10. So Interlocked 8 16 Any Evidence Of Condensate Formation 8 17 c Any Evidence Of Condensate Leakage 8 18 Any Evidence Of Water Leakage 8 19 Any Evidence Of Flue Gas Leakage 8 20 Has Boiler Been Built And Cased Correctly Is Gas Service Cock Installed If So Is It Accessible 8 22 Is Oil Filter Fitted 8 23 Is Fire Valve Fitted J Single Pipe TwoPipe J es TNO Is The Installation Safe For Use If The Answer Is NO Has A Warning Label Been Raised Is Any Remedial Work Reguired Have Warning Labels Been Fitted Has RIDDOR Form Been Raised CUSTOMER SIGNATURE PRINT NAME DATE ENGINEER DETAILS NAME COMPANY SIGNATURE NOTE 6 7 6 8 8 6 9 to be measured in secondary flue 600mm up from the flue socket or at the sampling point provided Normally 6 12 and 6 14 are recorded when tappings provided Position of measurement to be in accordance with boiler and or burner manufacturers instructions Fully Electric Boilers Thermo Electric Boilers Condensing Boilers Pressure Jet Oil O U 0 e x Items in italics are MANDATORY Note It is the installer s responsibility to ensure that the boiler is correctly commissioned by a competent engineer and that this report is completed as a permanent record A commissioning service is available from Potterton Commercial at the address listed
11. air Check pilot injector Check ignition electrode position Check electrical supply polarity Check earth continuity to pilot burner Check pilot burner pressure is correct Check there is no earth leakage on ionisation probe circuit Check ionisation probe circuit for correct flame current This is achieved by connecting a DC micrometer in series A reading of at least 7uA DC should be obtained If this is obtained and the control box continues to lock out then replace the control box Check main burner gas cock is open Check electrical continuity to main gas valve Check operation of gas valve and replace if necessary Check control box Replace if necessary Check ignition of main flame is smooth and reliable Check voltage supply for interference Faulty Control Box POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS COMPONENT REPLACEMENT Before commencing any component replacement isolate the electrical and gas supplies to the boiler After every service visit the soundness of the gas control assembly must be checked as described on page 31 Main Burner Bar 1 Remove the main burner assembly as described under Cleaning the Boiler on page 34 2 Refitting the burner assembly is the reverse of the above procedure Pilot Burner amp Electrodes 1 Release the pilot burner by unscrewing the union on the rear of the pilot burner then undoing
12. at the front of the inside panel using the M5 screws Fitting the sides on the rear panel using the M5 SCrews SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 20 DERWENT PRESTIGE PLUS C Prefit the M5 screws onto the left and right panels without tightening completely Position the slots on the panel casing on the 2 x M5 screws and the 2 pins D Tighten the 2 x M5 screws POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS E Insert the pins into the slots F Using the M5 lock from underneath G Check for the presence of the 3 way connector with Jumper H Assemble the front top by positioning the opening for the control panel on the right or on the left using the 2 M5 screws The control panel must always be fitted on the heating outlet side and the gas supply side e Position the eguipment according to right or left fitting SECTION 4 PAGE 21 Configuration Location of the thermostats Location of the thermostats and probes for this configuration configuration SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 22 DERWENT PRESTIGE PLUS I Position the control panel on the front top while routing the probe cables through the opening included to this effect Cables probes ee J Ins
13. box does not lock out see Fault Finding on page 36 Commissioning Live Run 1 Turn on the appliance isolation valve 2 Check the inlet pressure which should be at least 17 mbar on the inlet test pressure point and note the value 3 Close the pilot supply gas cock and check that the pilot pressure is zero and not moving 4 Turn on the electricity supply at the main isolator and at the on off switch on the control panel fascia ensuring that time clocks and any other external controls are made or are in the ON position also turn on the pilot isolation valve 5 Approximately 15 seconds after switching on the ignition spark should appear followed by ignition of the pilot burner If pilot flame is not established the control box will lockout the red lockout light on the control panel will illuminate This may initially occur due to air in the pilot line 6 The control box may be re set after a delay of one minute by pressing the red button on the control panel and the red light will go out When the flame is established and the main burner is lit check the gas pressure on the gas manifold pressure nipple and adjust the regulator located on the gas valve see page 30 to give a pressure of 16 5 mbar An ignition spark should start followed by lockout 7 The pilot burner will re light followed 10 15 seconds later by the main burners SECTION 4 PAGE 32 8 For high low operation the low fire rate must be set first
14. by an appropriate insulation BURNER INFORMATION The Derwent Prestige boiler is fitted with low NOx Furigas atmospheric burners NOx emission 70 120 mg kWh Class 3 certified to EN297 1994 A3 1996 SECTION 2 PAGE 6 GENERAL This boiler is NOT SUITABLE for installation in a normally occupied area i e kitchen A LIFETIME GUARANTEE is available on this boiler please refer to our standard terms and conditions for details The Potterton Derwent Prestige cast iron sectional boiler is available in twelve sizes from 133kW 9 section model to 348kW 22 section model Tables 3 page 2 and 4 page 3 give kW outputs and technical data for each model Nat Gas LPG 100 30 82 9 82 9 They are approved for use on open vented systems minimum head 5mm however they are suitable for use on sealed systems with a minimum operating pressure of 0 5 bar 0 1 bar Available on reguest and a maximum operating pressure of 5 bar 73 5 p s i Refer to relevant British Standards and Codes of Practice regarding the installation of Derwent Prestige boilers on sealed systems For sites with restricted access the boiler block with the burner and drain cock removed will pass through a 660mm doorway If necessary the boiler block can be easily stripped down into individual sections Each section weighs approximately 40kg and the principle dimensions are 800 x 500 x 80mm All assembled boilers are delivered with the gas train mad
15. of additional gas meters to assist in the monitoring of boiler performance Attention is drawn to the need for adequately sized pipework according to the maximum gas demand for multiple boiler installations and each boiler shall be provided with an isolating valve so that it is possible to isolate the boiler from a common gas supply for maintenance purposes Boosters will not be necessary if a minimum inlet pressure of 17 mbar can be provided at the inlet to each gas train and maintained during full load conditions If a booster is required the Local Gas Undertaking must be consulted and the booster shall be fitted with a low pressure cut off switch upstream of the booster in the event of reduced pressure and to prevent automatic restart on pressure restoration The cut off pressure shall be decided by the Local Gas Undertaking a DC PL ie a NM z links D and G and providing a switch across these terminals to switch the boiler Note this does not switch the pump circuit Safety Interlocks are provided across R 8 K for pressure switch etc The high limit thermostat and burner lockout signals can be picked up from terminals marked remote indication These are volt free contacis See boiler wiring diagram POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS Fig 26 Control Panel Configurations Pump Switch Not Used 2 Stage Indicator Light
16. on the front inner panel of the boiler For multiple boiler installations each boiler shall have an isolator and fuse as detailed above to protect the boiler and allow for maintenance Connecting the flue The fluehood has a vertical female outlet into which the flue should be fitted and sealed It is recommended that twin walled flue is used Find below guidance for flue installations It recommended the services of a flue specialist are used A POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS Connecting the Pilot Gas Line The pilot line is of sufficient length and is fitted with an isolating valve A piece of tube is supplied in the gas train box This is connected to the pilot burner and the pilot line by compression fittings Put the cap nuts on the tube then the olives and position both pipe ends right into the fittings before tightening Tighten the fittings together and do not use pipe jointing compound on these connections Finally connect the gas train plug to the boiler plug on the front panel Plug the ignition lead into the ignition probe then cut the ionisation lead to the required length see table below for details No of Wire Length with Left Wire Length with Right sections Hand Gas Train Hand Gas Train 12 to 14 2100mm 1600mm BOILER DISASSEMBLY 15 to 17 2300mm 1600mm 18 to 22 2600mm 1600mm If the boiler has to be disasse
17. 2 Stage Thermostat Green lndicator Light Showing 1 Stage Run If light flashes indication of overheat fault Pump Indicator Liaht Boiler Temperature Control Thermostat The CE 100 module provides the following functions Operation at 1 Stage Detection of boiler overheat ionisation probe fault Ability to restrict max boiler temperature using jumper at back of module Indication of the operation mode of the boiler Operation of 2 Stage operation Fig 27 The CB 120 module provides the following functions Reset button Overheat thermostat Overheat indicator Lockout indicator Mains supply indicator On Off switch Over ride button for safety checks Over ride thermostat set to the right maximum position allowing control by the 1 stage and 2 stage thermostats 9 6 3 Amp Fuse 10 Boiler thermostat o em s Dr SECTION 4 PAGE 29 Potterton Commercial Customer Commissioning Check List The items listed below have been put together as a guide to what actions should be completed before the commissioning of a boiler takes place 1 Site access available for persons carrying out the proposed work 2 Site Managers Personnel aware that work will be taking place 3 Boilers correctly erected and cased 4 Risk Assessments carried out on possible risks which may effect the persons carrying out the proposed work 5 Site wiring complete to boilers 6 Boilers filled amp vented
18. 45 22 Section COMN9171480 Combustion Front Plate Insulation 10 Section 1 8136767 _ Combustion Front Plate Insulation 11 Section 1 8136768 Combustion Front Plate Insulation 12 Section 1 8136769 Combustion Front Plate Insulation 13 Section 1 513600 Combustion Front Plate Insulation 14 Section 1 51367710 _ Combustion Front Plate Insulation 15 Section 1 8186772 Combustion Front Plate Insulation 16 Section 1 S136773 Combustion Front Plate Insulation 17 Section 1 8186774 Combustion Front Plate Insulation 18 Section 1 5136 50 Combustion Front Plate Insulation 20 Section 1 51367760 __ Combustion Front Plate Insulation 22 Section 1 5136770 Ignition Transformer __ Control Panel Cable 10 to 12 Sectio 1 X 51368200 __ Control Panel Cable 13 to 14 Section 1 S136821 __ Control Panel Cable 15 to 16 Section 1 5136822 __ Control Panel Cable 17 to 18Sectio 0011000 51368230 Control Panel Cable 20 to 22 Section Bag of Screws 15t018 COMI7881068 BagofScrews201022 1 1 COM178810600 Data Plate Not Shown COM17070892 SECTION 6 POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PA
19. ATION AND MAINTENANCE MANUAL PAGE 16 DERWENT PRESTIGE PLUS Stage 3 Insert the base tray inside the combustion chamber See Figures 6 7 slots Stage 4 When the base tray is in position fit the sealing tape on the front edge of the base tray using the adhesive and sealing tape provided See Figures 8 9 10 POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 17 Stage 5 The complete burner assembly can now be fitted to the boiler by locating the burner assembly on to the studs on the end sections See Figures 11 12 Slots For studs studs Stage 6 Connect the pilot tube of 4mm diameter to the 6mm pilot tube elbow and on to the gas valve by the BANJO Stage Connection See Figures 13 14 Banjo 6mm Connectionn Connection Boiler Maintenance It is essential that when the maintenance of the boiler takes place that the pieces of insulation are inspected and if they are showing any signs of deterioration they should be replaced Please refer to Boiler Maintenance on section 4 Page 34 SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 18 Burner Manifold The burner manifold T can be fitted with the gas inlet on the right or left lt is fixed to the front panel U by four nuts and washer spacers supplied Fig 18 Note on the 12 to 22 section boiler the gas train and the re
20. CTION 5 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 40 DERWENT PRESTIGE PLUS Fig 33 x 11213141516 ranami rabate 778 4 8 Sec 9 11 Sec 10 14 Sec TSB 12 22 Sec 15 22 Sec TSB DGAI Burner Control Box TTB Flue Safety Device ION lonisation Probe TSB Klixon TSB Klxom P Gas Low Pressure Switch Please be aware that the new control box used on the Derwent Range of products energises the fault indication on start up If the volt free connection for remote fault indication is used then a time delay must be incorporated on the BEMS side POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 6 INSTALLATON OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 41 Fig 34 Boiler Body RAI is ANS No Left Hand End Section Right Hand End Section Intermediate Section ependant FlowHeader 10 Section FlowHeader 11 Section Z o Zoo Flow Header 12 Section 1 FlowHeader 13 Section O 1 FlowHeader 14 Section O Z O Z FlowHeader 15 Section FlowHeader 16 Section O Z Flow Header 17 Section O Z o Z Flow Header 18 Section _____ Flow Header 20 Section Flow Header 22 Section Return Header 9 Section Return Header 10 Section o Return Header 11 Section 1
21. ECTION 4 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 13 b EYES the eye should be irrigated with water No Of B and medical treatment sought um sections mm c INHALATION continued exposure should be 272 A prevented and the user should be removed to open air and if necessary medical advice sought used to keep the rope in position until the sections are clamped together The adhesive should be used sparingly as it is only SI k 1053 The end sections should be at right angles to the floor and siting on steel strips required under the section feet see Fig 2 page 5 The sections should be spaced so that the distance between the centres of the end sections are as Dimension B 20mm in Fig 10 it is essential that this dimension is maintained at the top and bottom otherwise the bottom feet of the end sections may toe in and this will make fitting the base tray difficult The boiler should now be sitting in its final position to avoid further movement when fully assembled Take an intermediate section and hang it on to the front manifold against the left hand end section taking care not to snag and pull off the sealing rope Add all of the intermediate sections until the last one is in place While maintaining continuous pressure on the right hand section in the direction shown by the arrow Fig 11 slacken the assembly plate A slighily to enable the final section to be moved up t
22. Fig Fig Fig Fig Fig Fig N 0 0 D O CO CO CO OO CO CO CO Installing Multiple Unassembled Boilers14 Fig Fitting of Flue Hood amp Burners Boiler Maintenance Burner Manifold Combustion Chamber Front Plate Gas Train Handling 18 Flue Hood Assembly 19 Flue Hood Assembly Fig Fig 17 Minimum Clearance Multiple Boilers 14 15 16 GI Ol O PD aa N INDEX Page Assembly of Casing 9 22 Sections 19 23 Connecting the Water System 24 Fig 20 Connections 24 Connecting the Components to the Control Panel 24 Fig 21 Control Panel Connections 24 Fig 22 Connections 25 Connecting the Electrical Supply 20 Fig 23 Power Supply 20 Fig 24 Cable Paths 25 Assembling the Gas Train 26 Connecting the Flue 26 Boiler Disassembly 26 Connecting the Pilot Gas Line 26 Fig 25 General Arrangement of Pilot Burner 27 Connecting the Gas Supply 28 Boiler Controls 28 Fig 26 Control Panel Configuration CE100 29 Fig 27 CB120 29 Potterton Customer Check List 29 Commissioning 30 Important Safety 30 Emergency Instructions 30 Additional Checks 31 Pre Lighting 31 Commissioning Live Run 31 Setting the Gas Valve 32 Fig 28 Dungs MB ZRDLE 32 Reduced Rate Setting 33 Fig 29 Gas Train 33 lonisation Current Check 33 Flue Spillage Test 33 Ventilation Checks 33 Operating of Ancillary Controls 33 To Light Boiler Normal 33 To Shut Down Boil
23. GE 44 DERWENT PRESTIGE PLUS Fig 35 Boiler Body 21 Pilot Gas Cock No mu p __ Mounting Plate 13 Section 0000 p 4 a Mu uu POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 6 INSTALLATON OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 45 N 1 Mounting Plate 20 Section COMN9253960 Mounting Plate 22 Section COMN9253970 EC NN 2 O MEME p RENE NEN Burner Back Plate 15Secion Burner Back Plate 16Secion Burner Back Plate 17Secion _ Burner Back Plate 18 Section Burner Back Plate 20Secion __ Burner Back Plate 22 Section __ Burner Mounting Plate Insulation 10 Section __ Burner Mounting Plate Insulation 11 Section __ Burner Mounting Plate Insulation 12 Section __ Burner Mounting Plate Insulation 13 Section __ Burner Mounting Plate Insulation 14 Section __ Burner Mounting Plate Insulation 15 Section __ Burner Mounting Plate Insulation 16 Section __ Burner Mounting Plate Insulation 17 Section __ Burner Mounting Plate Insulation 18 Section __ Burner Mounting Plate Insulation 20 Section __ Burner Mounting Plate Insulation 22 Section __ Insulation Strips 10 Section 000000 __ Insulation Strips 11 Section 00000 __ Insulation Strips 12 Section 00000 _ Insula
24. LET Pressure Switch 4 67 Check oil available at burner Settings Check gas meter fitted amp sized ma adequately 8 0 BOILER SYSTEM CHECK LIST Conventional 8 Control Thermostat Setting Je Room Sealed 82 High Low Thermostat Setting PE Flue Fan Dilution System 8 3 Boiler WaterPressue CT o y O Type Balanced Compartment _ 8 4 Are Pipework Connections As Per Manual Plant Room Door Interlocked Is Safety Valve Fitted Fan Assisted i If So SIZE amp MAKEB anna anna anna ana 5 2 Draught Stabiliser Fitted PRESSURE RATING 5 3 Is Flue System Clear LL TES NO 5 4 8 6 Are Water Isolating Valves Fitted Flue Header Diameter Are Water Flow Switches Fitted Are Return Water Shut Off Or Diverter Valves 8 8 Fitted 89 Is Shunt Pump Fited 8 10 Is Pump Overrun Fitted SYSTEMWATEROUALITY 8 11 PHValue pH Approximate Overall Height m 812 TDS PPM Ri mmen DIAMETER mm Where appropriate and for multi boiler installations sketch details of flue system showing length of runs and diameter COMMISSIONING REPORT Continued Comments On Accessibility For Maintenance EDS Ka aaa Is The Fan Interlocked With The Boiler Are Flue Dampers Fitted If So Are They Interlocked Fan Assisted Ventilation BEEN ACER om If
25. To be kept by the user March 2010 Derwent Prestige Plus Installation operation amp maintenance manual VVorking towards POTTE TON A Cleaner TUTU O heating specialists Section 1 Fig 1 General Data amp Dimensions Table 1 Boiler Dimensions Table 2 Connections Table 3 Technical Data 9 to 12 Section Table 4 Technical Data 13 to 22 Section Fig 2 Steel Base Strip Details Clearances 8 Burner Info Section 2 General Information Standard Supply Controls Shipping Packaging Installation Boiler Siting 8 Base Section 3 Ventilation Flue Size Considerations Common Flue Systems Water Circulation systems Boiler Protection System Water Ouality Sealed Systems Section 4 Boiler Erection Risk Assessment Manual Handling Personal Protective Eguipment Confined Spaces Electrical Safety Preparation C O S H H Erection Assembly Checklist Heat Exchanger Assembly Assembly of Boiler Block Section Assembly 1 Stud Fixing Section assembly 2 Section assembly 3 Section Assembly 4 Sealing Cord Section Assembly 5 Fitting the Seals 10 Section Assembly 6 11 Section Assembly 7 12 Section Assembly 8 13 Section Assembly 9 14 Section Assembly 10 15 Section Assembly 11 Combustion Chamber Base Plate Hydraulic Test of Boiler 16 Ceramic Felt Assembly Fig 3 Fig 4 Fig 5 Fig 6 Fig 7 Fig 8 Fig 9 Fig
26. anel 9Section TopPanel 10Secton _ TopPanel 11 Section Top Panel 12 Section _ TopPanel 13Section Top Panel 14 Section TopPanel 15Secton _ TopPanel 16 Section o _ TopPanel 17 Section _ TopPanel 18 Section _ TopPanel 20Section Z o TopPanel 22Secton o 7 Top Front Panel 9 Section TopFrontPanel 10 Section TopFrontPanel 11 Section Top Front Panel 12 Section _ Top Front Panel 13 Section _ Top Front Panel 14 Section Top Front Panel 15 Section _ Top Front Panel 16 Section _ Top Front Panel 17 Section _ Top Front Panel 18 Section _ Top Front Panel 20 Section Top Front Panel 22 Section 8 Control Panel Housing 9 Section _ Control Panel Housing 10 Section __ Control Panel Housing 11 Section __ Control Panel Housing 12 Section _ Control Panel Housing 13 Section _ Control Panel Housing 14 Section _ Control Panel Housing 15 Section _ Control Panel Housing 16 Section __ Control Panel Housing 17 Section __ Control Panel Housing 18 Section _ Control Panel Housing 20 Section 0 __ Control Panel Housing
27. ated are minimum sizes for single boiler installations MINIMUM RETURN TEMPERATURE If system return temperatures below 55 C are required then contact the Potterton Commercial Technical Department WEIGHT The dry weight is inclusive of the gas train Each section measures approximately 800mm high x 500mm wide x 80mm deep and weighs approximately 40 kg ANY PERSON OR PERSONS MOVING OR LIFTING SHOULD BE TRAINED IN MANUAL HANDLING TECHNIQUES AND IF NECESSARY USE SUITABLE LIFTING EQUIPMENT TO REDUCE THE RISK OF INJURY TO THEMSELVES OR OTHER PEOPLE POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 1 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 5 Fig 2 Steel Base Strip Details The Derwent Prestige is designed to be installed directly on the boiler room floor provided that it is adeguate See page 7 Boiler Siting 8 Base F X II Centre Line l 710 I Of Boiler The boiler feet must never be fixed in position this is to allow for expansion CLEARANCES The minimum boiler room clearances for access erection and maintenance are as follows REAR 300mm from rear of flue hood SIDES 750mm on gas train side 200mm on the other FRONT 700mm to allow for burner removal TOP 1000mm to allow for cleaning MAD SF Flammable products should never be stored in the space around the boiler Any walls that are sensitive to heat should be protected
28. ation that all electrical checks have been carried out 2 Gas supply is tested for soundness and purged of air Ensure that the burner is suitable for connected gas supply and pressure 3 Test for gas soundness of gas trains as described on page 31 4 Appliance gas cocks are all turned off 5 Gas supply is turned on at the meter 6 Boiler and system are filled with water and operating pressure is within appliance range 7 Flow and return valves are open 8 Any external controls and the on off switch are in the ON position 9 The circulating pumps are operational Check that the pump is scheduled to run and not on pump overrun if the boiler has previously been fired Check that any flow proving interlocks are functional 10 Check that the high limit thermostat has not tripped by pressing the green reset button underneath the hexagon cap nut on the fascia 11 Ventilation is adeguate and in the case of mechanical ventilation systems operation of the boiler is inhibited unless the ventilation fan is proved 12 On mechanically assisted flue systems the operation of the boiler plant should be inhibited unless the mechanical flue system is operational and flow proved POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS 13 The safety valve should be checked to ensure that it is the correct size and pressure 14 The cold feed and open vent sizes sh
29. d due to failure then the cause should be investigated before installing new boilers 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 SECTION 3 PAGE 9 Where an old system shows evidence of contamination then system cleaning should be carried out before installation of new boilers The heating system should be chemically flushed to remove any lime scale or corrosion and a corrosion and lime scale inhibitor added Lime scale descalers if incorrectly used could cause any remaining system debris to continue to breakdown and contaminate the new boiler causing boiler failure Advice on system cleaning and suitable products should be sought from specialist suppliers of system cleaners such as Fernox or Sentinel It is important to note that corrosion inhibitor can only be used in an attempt to prevent corrosion from occurring where a system has an existing corrosion problem inhibitors will be ineffective and the system reguires cleaning On existing systems where comprehensive descaling and desludging cannot be carried out then consideration should be given to separating the new boiler system from the existing system pipe work by
30. e Hot Water Systems BS 779 1989 Cast Iron Boilers for Central Heating 8 Indirect Hot Water Supply Rated Output 44kW and above CP342 2 Centralised Hot Water Supply Gas Safety Installation amp Use Regulations 1994 IM 11 Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters IGE UP 1 Soundness testing amp Purging Procedure for Non Domestic Installations IGE UP 2 Gas Installation Pipework boosters Compressors in Industrial amp Commercial Premises BS 7671 1992 Requirements for Electrical Installation IEE Wiring Regulations 16 Edition Manufacturers notes must not be taken in any way as overriding statutory obligations BOILER SITING amp BASE The boiler should be sited in accordance with BS 6644 2005 with respect to protecting the boiler from damage air for combustion and ventilation discharge of products of combustion clearances for service and access temperatures noise levels the disposal of boiler house water and the effects of flooding of the boiler house or seepage from a roof top boiler house See section 1 for required boiler clearances for service and cleaning A level non combustible floor capable of supporting the weight of the boiler filled with water see Table 3 page 2 and 4 page 3 together with any additional weight bearing down on the base from connections etc must be provided This should be of an adequate height above the floor so as to be raised in the case o
31. e electrically competent and adhere to the IEE Regulations Boiler log book supplied Manual Handling Any person or persons moving or lifting the boiler or any part of it should be trained in manual handling techniques and if necessary use Suitable lifting equipment to reduce the risk of injury to themselves or other people The installation should comply with the relevant British Standard Specifications Codes of Practice and current Building Regulations together with any special regional requirements of the local authorities gas undertaking and insurance company All electrical wiring must comply with I E E Regulations for the Electrical Equipment of Buildings The installation of the boiler must be in accordance with the relevant requirements of Health amp Safety at Work Act 1974 BS 5440 1 2000 Specification for Installation of Flues Building Regulations 2006 Electricity at Work Regulations 1989 Management of Health amp Safety at Work Regulations 1992 Manual Handling Regulations 1992 Model Water By laws 1986 BS 5440 2 2000 Specification for Installation of Ventilation for Gas Appliances BS 6644 2005 Installation of Gas Fired Hot Water Boilers for Inputs between 60kW and 2MW BS 7074 1989 Part 2 Application Selection 8 Installation of Expansion Vessels a Ancillary Equipment for Sealed Water Systems SECTION 2 PAGE 7 BS 6880 1988 Codes of Practice for Low Temperatur
32. e overheat thermostat knob and press the reset button The use of a primary loop system is highly recommended to provide a constant boiler flow rate SECTION 4 PAGE 35 under all operating conditions For further information refer to Potterton Publication technical Bulletin No 1 latest issue Burner Lockout The boilers have an integral safety system to allow the safe and reliable operation of the burner Failure of the burner to operate correcily will cause the burner control box to lockout and the lockout light on the boiler control panel will illuminate to indicate this Pushing the rest button can manually reset the lockout condition and the control box should restart its control sequence in an attempt to light the burner If the control box will not reset or goes to lockout after being reset then the services of a boiler repair maintenance company should be sought This service is available from Potterton Commercial service offices details of which can be found on the back page of this manual WARNING The lockout reset button should not be repeatedly operated otherwise a hazardous situation may occur Should the boiler go to lockout check the following before attempting to re light the burner 1 The gas meter pressure is above 17 mbar 2 The electrical supply to the appliance is of the correct voltage and polarity The Derwent Prestige boiler is fitted with a Dungs DGAI 65F control box The control box cont
33. e to the left hand side The Electrical connection to the gas train assembly must be connected on site by an in line plug and socket which is connected to the control panel as delivered On the 20 and 22 section boilers the flow and return connections cannot be made on the same side of the boiler they must be diagonally opposite On the 12 to 22 section boilers the return connection and gas train CANNOT be on the same side of the boiler The boiler sections are cast iron with pips to aid heat transfer and they are joined by EPDM flat sealing washers to flow and return manifolds The boiler sections are insulated by 50mm glass fibre insulation The case is finished in a powder coat paint as follows POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS Red RAL 3001 Grey Non Standard but closest match RAL 7024 Assembled Boiler STANDARD SUPPLY Cast iron sections Flue hood Insulated painted steel case Eco control panel Cleaning brush Drain Cock CONTROLS The fully automatic control system which incorporates full safety features includes control and high limit thermostats thermometer and burner on off switch All models have automatic ignition with a sequential control box and an ionisation flame failure device fitted to an interrupted low energy pilot burner Including two volt free remote status contacts OPTIONAL EXTRAS Sequence c
34. er 33 Setting the Flow Temperature 34 Fig 30 Control amp High Low Thermostats 34 Water Flow Switch 34 Boiler Maintenance 34 Boiler Cleaning 34 Fault Finding 35 Overheat Operation 35 Burner Lockout 35 Fault Finding Check List 36 Component Replacement 37 Section 5 Main Gas Line Components 38 To test for Gas Soundness of Control Assembly amp Safety Shut Off Valves 38 Fig 31 Gas Train Configuration 38 Fig 32 Wiring Diagram 39 Fig 33 Wiring Diagram 40 Section 6 Spares Lists Fig 34 Boiler Body 41 Fig 35 Boiler Body 44 Fig 36 Casing Assembly 47 Fig 37 Flue Box 50 Fig 38 Control Panel 52 Fig 39 Gas Valve 53 POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 1 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 1 Fig 1 General Data amp Dimensions mm NOT TO SCALE Drain 34 Return Gas Connection Table 1 Boiler Dimensions EI NENE RANA KARA NARA KE Sections From the 12 section the gas and return connection cannot be made on the same side Table 2 Connections 208 22 Section flow and return are screwed flanged connections mating flanges supplied Note Only one flow and one return connection can be used Refer to page 18 for details on handling options for boiler flow and gas connections SECTION 1 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 2 DERWENT PRESTIGE
35. eration of an air flow switch on a mechanical ventilation system 2 That the chimney system is sound and adequately evacuating the products of combustion and that there is no spillage of flue producis 3 That the burner gas pressure is correct and that the boiler is still on rate 4 That the low pressure switch on the boller if fitted is operating correctly 5 That the water flow switch if fitted is operating correctly To clean the boiler it will be necessary to remove the boiler flue hood cover and burner assembly as detailed below Ensure boiler is isolated from all supplies 1 Remove the boiler door by lifting forwards and upwards disconnect earth wiring and chain 2 Hemove side front panel bottom fixing screws then lift upwards and forwards 3 Remove the pilot gas pipe on the 90 elbow close to the union nut support the gas train and undo the gas union on the burner manifold 4 Unscrew the nuts on the burner mounting plate on right and left hand sides of the mounting plate 5 Disconnect the spark ionisation and earth wires to the pilot burner 6 Pull the burner assembly forward and clean the burner pilot burner and combustion chamber of dust and debris POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS 7 Clean the burner bars and ensure that the holes slots are clear If necessary blow the slots and internals clear with compres
36. ert the pins under the panel into the slots and pull the control panel towards you for right hand side configuration or push it for a left hand configuration Lock it using a M5 screw on the top front K Run the probe cables in the casing and introduce the thermostats into the thermostat pocket or left according to the position of the control panel L Secure the casing panel using a M5 screw POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 23 M Insert the right and left removal panels onto the pins and secure with the M5 screws Fit the pint screws Screw the chain under the casing panel N Insert the panel onto the pin screws and hook the chain into the hole located under the quarter turn screw phocoNO4COE PSD 7 t o O Lock the panel using the guarter turn screws Ouarter tum screw P Slide the top rear panel forwards and lock it using the stoppers SECTION 4 PAGE 24 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL Connecting the Water System The flow and return connections should be made to the appropriate manifolds For 20 and 22 section boilers the connections should be made to the flanges provided which are fitted to the manifolds It is essential that all pipework connections to the boiler are self supporting correctly aligned and allow for free expansion o
37. f flooding but low enough to allow ease of erection Typically a 50mm concrete plinth with an area equal to that of the plan of the boiler is adequate in most cases Heating systems must be installed so that water cannot be returned from the heating system to the drinking water system to which it is connected to prevent the drinking water being contaminated by the heating water or chemicals used in the heating water Steel strios should be provided not supplied by Potterton Commercial to support the left and right hand section feet and the back feet of the intermediate sections see Fig 2 page 5 for details These strips should typically be 75mm wide and 5mm thick L P G boilers MUST NOT be basements below ground or in a well installed in SECTION 3 PAGE 8 For further advice on installations refer to the relevant Potterton Application Guide VENTILATION Safe efficient and trouble free operation of conventionally flued boilers is vitally dependent on the provision of an adeguate supply of fresh air to the room in which the appliance is installed Account must also be taken of any other fuel burning appliance existing or to be fitted when designing the ventilation and combustion air systems IMPORTANT The use of an extractor fan in the same room as the boiler or in an adjacent room in communication can in certain conditions adversely affect the safe operation of the boiler and therefore must be avoided Furthe
38. f both boiler and pipework Care should be taken in the pipework design to prevent strain on the connections Excessive strain can lead to premature failure of the boiler which is obviously outside the terms of our warranty The use of expansion bellows to take up both axial and lateral movement is recommended Fig 20 Flow Connection Drain Connection DERWENT PRESTIGE PLUS Connecting the Components to the Control Panel Valves 9 channel connector Gas pressure switch 6 changeel connector Connect the ignition cable left electrode and ionisation cable right electrode to the intermittent pilot burner assembly Connect the burner safety thermostat cable Assemble the thermostat phials thermostat and control probe optionally in the thermostat pocket as indicated in the following diagram Fig 21 Control Panel with Control Panel Sequence Controls Boiler thermostat pocket without sequence probe Boiler sequence thermostat pocket with sequencing When fitting capillaries ensure they are positioned at the bottom of the thermostat pocket 1 Overheat safety thermostat 2 Heating outlet thermometer 3 Control thermostat 4 g 6 tube 5 Sequence control probe POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 25 Connections Fig 22 Connect the burner safety thermostat 2 way I con
39. for all boiler maintenance amp 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 lf this is impractical then suitable precautions must be undertaken to prevent injury In the case of 2 above checks are specified to identify any abnormality in the electricity supply to the boiler as well as to confirm that the boiler electrical connections are reinstated correctly where it is necessary to disconnect or reconnect any internal wiring within the boiler If it is necessary to disconnect and reconnect the appliance from the site electrical installation other than means of a plug and socket then additional checks shall be undertaken by an approved engineer to check the earth loop impedance in accordance with IEE regulations Always carry out preliminary electrical safety checks All appliances and central heating systems must be provided with their own means of isolation for safety purposes especially during installation and maintenance Preparation Before the installation of the boiler a check must be made to ensure that suitable facilities are available for off loading the boiler the 9 to 16 section boilers come with assembled hea
40. for efficient and trouble free operation that the boiler plant is regularly maintained This must be carried out by qualified and experienced engineers and in the case of gas fired appliances attention is drawn to the mandatory requirement of CORGI Council of Registered Gas Installers registration of personnel undertaking work on these appliances This facility is available from Potterton Commercial details are available from the service offices listed on the back page of this manual Boilers should be serviced and re commissioned as a minimum on an annual basis but frequency may depend on usage and application of the boiler It is strongly advised that a maintenance contract be entered into with Potterton Commercial Division to ensure that the boiler ourner unit is correctly and properly maintained POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS WARNING Isolate the electrical and gas supplies before attempting any maintenance work Following completion of maintenance on the boiler the boiler should be re commissioned as detailed below BOILER CLEANING At every service visit the boiler should be cleaned as detailed below and the soundness of the gas control assembly must be checked The boiler should be fully re commissioned as described below with attention also paid to 1 The effectiveness of natural and mechanical ventilation and in particular the safe op
41. heck that the air is in the draught diverter and that combustion products are not spilling out of the draught diverter The flue draught should be checked with a draught gauge and a draught of 1mm w g Is required and should be measured at a suitable test point in the flue above the flue adaptor socket SECTION 4 PAGE 33 Ventilation Checks For boiler houses with natural ventilation the area of the grilles should be checked against the figures given for ventilation on page 2 8 3 or BS6644 For boiler houses with mechanical ventilation the suitability of the ventilation and extract system should be checked against the sizes given for mechanical ventilation on page 2 8 3 or BS6644 In addition the installer should check that it is not possible for the boller to operate if either the ventilation or extract fans are not running THE BOILER SHOULD NOT BE OPERATED WITHOUT ADEQUATE VENTILATION OPERATION OF ANCILLARY CONTROLS After lighting the boiler the operation of the above mentioned controls e g clock and thermostats should be checked TO LIGHT BOILER NORMAL OPERATION 1 Check that the pilot gas cock and the service gas cock at the meter are on 2 Check that all ancillary controls e g time clocks are turned on 3 Check that the electricity supply is turned on 4 Switch on the on off switch 5 Check that the control panel lockout lamp is not lit and if so reset by pressing reset button 6 Turn the b
42. hen retighten the clamping plate Fit the 3 tie bars one at the front and two at the back Loosen the two clamping plates fit the base tray in position and tighten the tie rods on the boiler up to dimension B Fig 10 Check this dimension carefully and check that the sections are at right angles as shown in Fig 12 Fit the return manitold E Fig 13 Centering the 34 hole drain positions the manifold accurately with respect to its clamping plate F Fit the clamping plate using just 2 nuts at each end Fitting the Seals Pull the return manifold about 15 to 20mm away from the cast iron heat exchanger using a lever chisel or screwdriver Insert the seals at an angle locating the bottom in the recess and letting the top rest against the manifold Fig 13 8 15 SECTION 4 PAGE 14 NOTE Do not use glue or mineral grease that might attack the EPDM seals Only the Vaseline supplied should be used in contact with the seal Fit the washers and nuts and tighten until the seals are in contact but without clamping the manifold Ensure that the tie rods T are taking the strain and then remove the assembly plates A from the outlet manifold and fit the clamping plate G Fig 10 Fit the seals in the same way for the outlet manifold Fig 14 8 15 Once the heat exchanger has been assembled but not clamped the sections can be shaken down by tapping repeatedly on the sides Check Once Again a That length
43. k for leaks with a soap solution or other approved method If no external leaks are detected the 1 Safety Shut Off Valve G1 is passing gas and should be replaced 2 Safety Shut Off Valve Gas Soundness Fit a pressure gauge to PTP2 ensure that the gauge pressure is zero Close the pilot isolation valve Open the appliance isolation valve and start the boiler the pressure should rise to line pressure and stay stable Observe the pressure gauge for 2 minutes Close the appliance isolating valve If a fall in gauge pressure is observed then the ond Safety Shut Off Valve G2 is passing gas and should be replaced Once the soundness test has been successfully completed tighten the pressure test points and check for leaks with soap solution or other approved method Assembled Gas Train Safety Shut Off Valves Gas Appliance Isolation Valve PS SNL RE ERREUR ar ka PTP5 ZRDLE Main Burner Manifold Pilot Burner Pilot Isolation Valve POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 5 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 39 Burner fault relay eru 4 Overheat relay TER al mms mmm oi HE ooo pro T I 11213 41516 111614 517 alo 10112131112 Pump Switch Overheat Thermostat 1 Stage Control Thermostat Overide U V 2 Stage Control Thermostat Burner Test Switch su Fuse CE100 Fuse Control Interlock Mains Indicator Light SE
44. ld be given V When boilers are to be stripped and rebuilt labour and transport should be provided for moving the sections from the delivery point to the final erection point If this is unable to be provided notice prior to attending site should be given VI Sections casing etc should be kept in a clean and dry area prior to erection assembly VII Water should be avallable VIII A drain off area should be available IX Power should be available X A site representative should be available at all times XI Clear instructions supplied to the persons carrying out the proposed work regarding positioning the boiler XII Fire evacuation procedures facilities availability specific Health a Safety information etc should be provided ltems VII to X are essential if boilers require pressure testing SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 12 Heat Exchanger Assembly Models 9 section to 16 section come delivered with the heat exchanger already assembled The control panel gas train and casing are packed separately and clearly labelled Models 17 section to 22 section are delivered unassembled The flue hood gas train burners casing and control panel are delivered on one pallet Provided below is a detailed assembly instruction procedure for erecting the boilers It is advisable to read the instructions fully before starting assembly Assembly
45. liance under full and part load operation is designed to a minimum It is recommended that the services of a specialist flue system manufacturer are sought for the design of common flue systems For initial flue design a flue size equivalent to the total free area of the boiler flue outlet should be used as a minimum For further information regarding ventilation amp flueing see Potterton Application Guide current issue or see relevant British Standard Publication BS6644 2005 THE ABOVE RECOMMENDATIONS ARE FOR GENERAL GUIDANCE ONLY POTTERTON COMMERCIAL DIVISION CANNOT ACCEPT RESPONSIBILITY FOR FLUE SYSTEM DESIGNS BASED ON THE ABOVE RECOMMENDATIONS WATER CIRCULATION SYSTEMS The water circulation systems should be indirect and installed in accordance with the relevant parts of British Standards Codes of Practice CP342 and BS 6644 1991 The maximum and minimum design temperature differential across the boiler should be 20 and 10 POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS and the boiler should be prevented from operating with flow rates giving a temperature difference across the boiler greater than 25 C based on the full boiler output Boilers operating under constant flow conditions can be more accurately controlled and are not subject to excessive temperature stresses The boilers MUST NOT be fired under any circumstances with less than the mini
46. llowing commissioning the boiler overheat and control thermostat should be set to the reguired operating setting 6 Following completlon of commissioning the soundness of all automatic fuel valves should be checked for leakage Additional Checks Where possible the system should be checked to ensure that following purging of alr there Is no raw water make up ln particular when the system is operated in the hot condition there should be no discharge of water from the safety valve open vent or cold feed tank overflow that would otherwise lead to unregulated raw water make up when the system cools down Pre Lighting Before attempting to light the boiler start the circulating pump and check that it is scheduled to run and not on pump overrun if the boiler has been fired previously Check that the main and pilot gas cocks and electrical supply are turned off SECTION 4 PAGE 31 Set the boiler control thermostat to the reguired position and the time clock to the ON position Check that the high limit thermostat has not been tripped by removing the hexagon cap nut and pressing the button beneath it Start the boiler by switching on the main isolator and the on off switch on the boiler control panel fascia and the boiler will attempt to light After a delay of approximately 15 seconds the ignition spark should be heard and after 5 seconds the control box should lock out If the ignition spark is not detected or the control
47. ly Main Gas Valve Typ 0017 Nett Flue Gas Temperature dq 19 O Flue Draught nina 2 9 Pilot Gas Valve Type amp Size JE CO At Flue Dilution Outlet 717717 7 2 10 Gas Booster Type 8 Size 6 14 Burner Fan Static Pressure Gas Booster Serial No Combustion Chamber Resistance mwg BURNER SETTINGS Main Burner Injector Size OPERATIONAL SAFETY CHECKS Check Control Thermostat Operation aM ag Electtode onisation Seting 2 Check Limit Thermostat Operation 74 Check For Gas Leaks 7 5 Check For Gas Leakage Past Valve Assembly ype 7 69 Check ForOilleaks SOME See Notes i the relevant B S Check For Flue Spillage Electricity supply fused isolated amp 7 12 Check Thermocouple Operation earth wire connected 7 18 Check Thermocouple Interrupter Operation Class C Class D Check Boiler Locks Out On Loss Of Flame Signal Check boiler Locks Out On Air Pressure Switch E i Operation Check Boiler Inhibits On Gas Inlet Pressure Switch OJ A A A M o g Check external controls allow 7 14 Check Gas Booster Interlock Operational operation Record Booster INLET and OUTLET Pressure Switch Check boiler system filled and pumps Settings operational 8 any isolation valves open OO INLET BB OU TEE nan A 45 Check gas available at burner Record Burner Boiler INLET and OUT
48. mbled it should be noted that the sections are not self supporting Remove the return manifold only and then remove the sections individually from the flow manifold The boiler is supplied with a Dungs gas train for high low operation Remove the gas train from its box and remove the boiler door The pilot supply pipe is also in the box with the gas train The pilot is supplied fixed to the burner for the left hand gas train arrangement If the gas train is to be fitted on the right hand side swap the pilot over to the right hand side The pilot is secured by two studs washers and nuts A blanking plate is similarly fastened to the redundant pilot mounting hole and should also be swapped over Remove the plastic plugs in the gas train union and fit to the union on the burner manifold Make sure the rubber seal is fitted in the union it can be found attached to the gas valve If the gas train has to be fitted on the right hand side the burner manifold should be changed over first NOTE The gas train is not self supporting and must be supported with the main gas pipework POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 27 Fig 25 General Arrangement of Pilot Burner Earth Electrode 7 lonisation Electrode Ignition Electrode S U gt O O CU E E ce SECTION 4 PAGE 28 Connecting the Gas Supply The connec
49. mom I TN rr prora e m om PO Diverter Socket to BS 835 Om DESE TAT 8 EA E SILA ELAN Flue Draught Requirements Flue Draught Requirements O Requirements 1 4mm ALL SIZES Ni Level Natural Ventilation to BS 6644 Low Level Natural 1512 e es Ds 1008 1080 1152 1224 1368 og Mechanical Inlet to BS 6644 ea 0 168 0 182 0 196 0 210 0 224 0 238 0266 266 0 294 294 a 2 E rip opa Flow at 25 C At lit sec 1 PT 2 15 2 3 246 2 EJ 2 P 1 8 Hydraulic Resistance at 11 C At KPa Resistance at 11 CAt kPa 25 83 83 29 22 29 22 TA TA 1 36 93 93 36 93 41 32 141 32 456 6 39 09 09 48 15 15 Cold Feed Size to BS 6644 PR Minimum Bore Open Vent Size to BS 6644 la Minimum Bore Safety Valve Size to BS 6644 Nominal Size ka Minimum Return Temperature um Cm m me sm se om mn n Wwe a per ne s sos es sz os s T Power Requirements 280V SoHz IPh Isolator and 6 3 fuse require oee Page 4 for explanatory notes Conversion table on inside of back cover SECTION 1 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL 10 11 PAGE 4 DERWENT PRESTIGE PLUS FUEL CONSUMPTION Gas fuel consumption is based on natural gas with a gross calorific value of 38 6 MJ ms The gas rate should be corrected for the meter supply pressure particularly on high pressure supplies to prevent overfiring MINIMUM OPERATING PRESSURE This is the minimum operating
50. mum water flow On systems with variable flow rates due to flow reducing devices ie TRVs zone valves etc or where the minimum heat demand ie summer domestic hot water load does not achieve the minimum boiler flow rate then consideration shall be given to incorporating a primary loop system For further information see Potterton Application Guide lt is recommended that the system is designed to give a constant flow rate For further information on water circulation systems see Potterton Application Guide BOILER PROTECTION The provision of pump overrun by a time delay relay or a thermostat situated in the flow pipe close to the boiler is essential to remove residual heat from the boiler The boiler and system should be protected by suitable frost thermostats Never fill a hot boiler with cold water Sudden cooling may cause the cast iron to fracture under the stress Unions and isolating valves should be fitted to the flow and return manifolds so that the boiler can be isolated from the system if the need arises SYSTEM WATER QUALITY High efficiency boiler systems require the water quality of the system water to be controlled by the use of inhibitors to maintain a neutral Ph and inhibit corrosion Additionally the water system should be free of leaks to prevent raw water make up which will dilute any inhibitors promote corrosion and form lime scale Existing Systems On existing systems where boilers are being replace
51. n the door 3 Remove the chain and earth wires and lift the door off 4 Remove the thermometer phial from the thermometer pocket and thread it through the grommet into the control panel 5 Push the thermometer from the inside to the outside by pressing the two clamps 6 Fit the new thermometer as the reversal of the above procedure The thermometer phial should be positioned as shown in Fig 21 page 24 Control Box 1 Remove the two screws securing the control panel fascia and hinge it down 2 Remove the two screws securing the control box base and then remove the control box 3 Disconnect the wiring connections 4 If the control box only is to be replaced fit the new box as a reverse of the above procedure 5 Replace the wiring in the same order Spark Generator 1 Release the guick release connection on the door by firmly pressing in and turn it one guarter turn to the left to open the door 2 Remove the chain and earth wires and lift the door off 3 Disconnect the spark generator connections from the control box base 4 Remove the four screws securing the ignitor to the front panel o Replace the spark generator as a reversal of the above procedure 6 Recommission the boiler as described on page 31 to check the operatlon of the control box SECTION 5 PAGE 38 Main Gas Line Components 1 Release the guick release connection on the door by firmly pressing in and turn it one guarter tur
52. n to the left to open the door 2 Remove the chain and earth wires and lift the door off 3 Unplug the electrical connection to the gas train 4 Release the burner manifold union and the pilot line connection to the pilot burner 5 Disconnect the gas train rear union upstream and lift away the gas train complete 6 Remove the cover plates and disconnect the electrical connections to the valve if necessary 7 Change the valves or governor as necessary 8 Remake the electrical connections and replace the pilot line and main gas line 9 After replacing the complete gas train check for gas soundness as described on page below TO TEST FOR GAS SOUNDNESS OF CONTROL ASSEMBLY amp SAFETY SHUT OFF VALVES To be read in conjunction with the schematic gas diagram Fig 30 IN ADDITION TO THE SPECIFIC VALVE PROVING TESTS BELOW ALL GAS JOINTS SHOULD BE CHECKED FOR LEAKS WITH A SOAP SOLUTION including the gas line to the pilot burner and main gas burner manifold Fig 31 Gas Train Configuration POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS 1 Safety Shut Off Valve Gas Soundness Fit a pressure gauge to PIP1 Open the appliance isolation valve Once a gauge pressure is observed close the appliance isolation valve Observe the pressure gauge for 2 minutes THERE SHOULD BE NO DROP IN GAUGE PRESSURE lf a drop in gauge pressure is observed chec
53. nal flue connection sizes are given in Table 3 and 4 these sizes refer to the boiler flue connection Socket detailed dimensions of the flue adapter to BS POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS 835 are given in table 3 and table 4 The actual size of the flue system will depend on individual site applications Detailed below are general considerations on sizing flue systems These notes are for guidance only and Potterton Commercial Division cannot accept responsibility for any flue system designs Horizontal Flue Runs Horizontal flue runs only add to the flue resistance without creating any buoyancy and must be avoided Sloping flue runs should not be less than 45 to the horizontal Flue resistance should be kept to a minimum but flues should not be oversized as this may lead to cold start spillage Where horizontal flue runs are unavoidable owing to building constraints advice should be sought from a flue specialist Common Flue Systems Where multiple boilers are installed on a common flue system then the flue system should be designed to ensure the correct operation of the flue on varying load conditions In particular that the appliance flue draught is within the operating parameter under full load and partial load conditions For safe and reliable operation of the boiler plant it is recommended that the variance in flue draught available at each app
54. nector marked UV he Gas pressure switch Control Panel 6 way connector Gas Valves Thermostat Pocket Ignition Plug lonisation Plug Burner safety thermostat plug 1 to 3 plugs according to model Connecting the Electrical Supply Fig 24 The electrical supply should be 230V 1Ph 50HZ A 6 3A fuse and a suitable two pole isolator having a Cable paths contact separation of at least 3 mm in all poles has to be provided by the installer for isolation of the boiler All on site wiring shall conform to I E E Regulations none the cables and the draft hooc The supply should be made to the right hand side of the boiler control panel by flexible conduit This can be achieved by removing the two screws from the front top corners of the control panel and hinging control panel front down and all the electrical connections can now be seen Fig 23 Main power supply Terminals for burner 230 Vac safely thermostat 5 phase impera ively n Lj SECTION 4 PAGE 26 Assembling the Gas Train The live neutral and earth connections should be made to the control panel terminal block The earth connection should be made 50mm longer The lengih of the conductors between the cord anchorage and the terminals must be such that the current carrying conductors become taut before the earth conductor if the cable or cord slips out of the cord anchorage The wiring diagram is included in this manual on page 39 amp 40 and also
55. of Boiler Block Remove the shrink wrap and metal straps securing the componenis to the pallet Identify the bag of fasteners thermostat pocket and spacers ceramic rope glue and Vaseline packed in the casing box Clean the sealing ring ports on the sections with a dry rag DO NOT use oil or any other compound Check that the sections are clear of swarf sand or any other debris The heat exchanger consists of three types of sections these being the left hand section L the middle section M and the right hand section R Fig 3 Fit the M10 studs shorter thread into the tapped holes in the sections Fig 4 Fix the outlet manifold D it has four W holes C to the right hand section using one of the assembly plates A Fig 5 amp 6 Note Ensure that the outlet is on the side which has been specified Fix it to the left hand section in the same way Fig 7 Add the sealing rope to the left hand side of the sections The rope is pre cut to two different lengihs one for the front and one for the back and should be glued with the adhesive provided and trimmed to length if necessary Fig 8 8 9 WARNING The adhesive gives of a flammable vapour and skin and eye contact should be avoided If the adhesive comes into contact with a SKIN then resin removing cream should be used and not a solvent to remove it DERWENT PRESTIGE PLUS Fig 6 Fig 7 POTIERTON COMMERCIAL PRODUCTS DIVISION S
56. oiler thermostat to the reguired setting 7 The boiler will now light WARNING If the pilot burner fails to establish or the boiler closed down after it has established or if the boiler closes down after the main flame has been established no attempt should be made to relight the boiler for a period of one minute TO SHUT DOWN BOILER 1 Temporarily Switch the on off switch to OFF Switch off the electrical supply 2 Long Periods As above but in addition turn off the service cock at the gas meter SECTION 4 PAGE 34 SETTING THE FLOW TEMPERATURE The reguired flow setting should be set by the control thermostat The temperatures that correspond to the positions on this scale are given in Fig 29 The boiler thermometer should be used to check and adjust the setting as necessary NOTE The high low operation works with two thermostats Low fire should be adjusted at a temperature between 0 C 8 5 C below the high fire temperature Fig 30 Control amp High Low Thermostats Giz High Low Thermostat Control Thermostat WATER FLOW SWITCH For boilers fitted with a water flow switch the installer should check that it is not possible for the boiler to fire when there is no water flow This may be done by checking the boiler closes down when the pumps are switched off or the water flow is gated off Always restore the water flow before completing commissioning BOILER MAINTENANCE It is essential
57. ommercial products Our service office offers a wide range of specialised services including e Burner commissioning for all fuels e Boiler service contracts e Breakdown and repair services e Burner and boiler replacement e Oil gas conversions e Water treatment and descaling e Packaged units All descriptions and illustrations contained within this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information in this leaflet delivering the spark Baxi Commercial Division Sales Wood Lane Erdington Birmingham B24 9QP Email potterton commercial baxigroup com www pottertoncommercial co uk 0845 0 0 1006 0845 0 0 1057 POTTESJON
58. on the back page of this manual When a Potterton Commercial engineer commissions the boiler this commissioning report will be filled in and left with the boiler Commissioning by Potterton Commercial engineers is restricted to equipment of our supply No responsibility will be accepted for the on site assembly or installation of the equipment unless specifically carried out by Potterton Commercial The installer must ensure that the boiler is installed in accordance with the manufacturer s instructions and all relevant B S Codes of Practice and Regulation see manufacturers instructions for full details PCF No 212 02 CONVERSION TABLE IMPERIAL TO METRIC METRIC TO IMPERIAL HEAT 1 Btu hr z 0 291 W 1 KW 3412Btu hr 1 Therm lt 100 000 Btu hr Btu 1055 J 1J 0 00094 78 Btu Btu hr 0 252 See Mal 1 kcal hr 3 968 Btu hr FUEL CONSUMPTION piane z Gm 1 m 35 3147 f 1 dm 1 LITRE UK Gall 4 546 litre 1 litre 0 2199 Imp 1 000 dm 1 m UK Gall 1 2 U S Gallon 1 U S Gallon 0 83 UK Gallon PRESSURE Ib in 6895 Pa 33 45 ft w g 1 PSI 2 307 FT Ib in 68 95 mbar 0 3345 ft w g 1 kPa 1000 Pa in w g 249 1 Pa 14 5 Ib in 1 bar 1000 mbar 100 kPa 1 in w g 2 491 mbar 0 358 in w g in w g 25 4 mm w g W 0 0394 in w g 9 8 Pa LENGTH inch 25 4 mm 0 03937 in 1m 1000mm 1 fi 0 3048 m 3 281 fi 1 vard 0 9144 m 1 094 yard 1 mile 1 609 km 06214 mile VOLUME 1 ft 0 02832 m 1m 35 3147 f
59. ontrols amp zone controls LPG Kits 9 to 11 Section 17405489 12 to 18 Section 17405494 10 to 22 Section 17405495 SHIPPING PACKAGING The 9 to 16 section boilers are delivered fully assembled with boiler burner and flue hood on a pallet plus separate cartons for gas train control panel and casing pack The 17 to 22 section boilers are delivered unassembled with sections flue hood burner gas train and casing pack on one pallet It is recommended that the Potterton Commercial Division s trained engineers should carry out erection and commissioning as this will make valid the LIFETIME GUARANTEE See back page of the manual for the addresses of the Service Office POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENACE MANUAL DERWENT PRESTIGE PLUS INSTALLATION The boiler should be installed in a CLEAN boller house free of dust and corrosive vapours During insulation of system plpework and heavy building construction work around the boiler the boiler must be switched off to avoid damage Before starting work a risk assessment should be carried out in the boiler house and its access to determine and ensure a safe installation and working environment Any person installing or working on the boiler must be gualified 8 competent and in the case of gas fired boilers attention is drawn to the mandatory requirement of C OR G I Registration ACS Qualifications Also they must b
60. ould be checked Following completion of the above checks the burner should be commissioned Typical combustion figures are detailed below The combustion figures etc should be completed on the commissioning form provided at the back of this manual and returned to Potterton Commercial at the address on the back page Commissioning figures should be taken at a boiler flow temperature of 80 C The combustion measurements should be taken in the secondary flue at a minimum of 600mm above the draught diverter GAS CO 6 7 CO 0 50 ppm Flue Gas Temp 130 160 C IMPORTANT The boiler burner units are manufactured in accordance with the company Guality Assurance plan registered to meet the reguirements of ISO 9000 A condition of this supply of the appliance for compliance with this Guality Assurance plan is the return of the appliance commissioning report Important Safety In the U K it is a legal reguirement that when working on gas appliances the engineer must be CORGI registered The manufacturer cannot be held responsible for any conseguential damage loss or personal injury as a result of customers failing to follow these instructions or as a result of misuse Emergency Instructions The burners are designed and constructed to meet all of the essential requirements of the GAS APPLIANCE DIRECTIVE 90 396 EEC and under normal circumstances should not give occasion to any hazardous conditions If such a condi
61. pply Elbow Klixon 100 4 C S502259 Klixon Cabling 9 Section Opa JJ as a aaa a as ss st onisation Lead Not Shown lonisation Lead Not Shown 0 I O 20 Klixon Cabling 10 to 12 Section _ Klixon Cabling 13 8 14 Section Klixon Cabling 15 8 16 Section __ Klixon Cabling 17 8 18 Section Klixon Cabling 29 8 22 Section pici 2 Pilot Isolating Valve Assembly Bag of Screws 9503294 POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 6 INSTALLATON OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 47 Fig 36 Casing Assembl S136810A S136809A S136418BB S136417BB S136487A _ FrontDoor 10 Section S136488A _ Front Door 11 Section S136489A _ Front Door 12 Section S136490A __ Front Door 13 Section S136491A p p p Item Description Quantity Red Casing White Casing No Part No Part No Front Door 14 Section S136492A S136492EE Front Door 15 Section S136493A S136493EE Front Door 16 Section S136494A S136494EE SECTION 6 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 48 DERWENT PRESTIGE PLUS Item Description Quantity Red Casing White Casing N Part No Part No 5 Front Door 17 Section FrontDoor 18 Section FrontDoor 20Section J Front Door 22 Section 6 TopP
62. pressure of the boiler with pumps operating NOT static pressure The requirements of the Health amp Safety Executive guidance note PM5 regarding maximum operating temperatures should be observed BOILER FLUE CONNECTION A spun aluminium flue adaptor is included for convenience that is designed to accommodate BS835 twin wall flue pipe It is not obligatory to use this adaptor but always ensure that the internal diameter of the flue used is no smaller than the connection on the flue collector hood see table 3 amp 4 for nominal flue connection size For transport the adaptor is tie wrapped to the flue hood FLUE GAS VOLUME Flue gas volumes are given at STP standard temperature and pressure 15 C and 1013 25 mbar Typical flue gas temperatures for flue sizing are 140 C at 6 5 CO with 1mm draught at the boiler flue connection NATURAL VENTILATION The sizes indicated are free grille areas and are based on a single boiler installation MECHANICAL VENTILATION The volume given is for a single boiler installation WATER CONNECTION SIZES The boiler water connections are screwed BSP connections up to 18 section and the 20 and 22 section sizes are flanged 2 with screwed counter flanges provided NOTE Only one flow connection and one return connection can be used on each boiler WATER FLOW RATES Water flow rates are given for boiler flow and return temperature differentials of 11 C COLD FEED OPEN VENT SAFETY VALVE SIZES Sizes indic
63. r Guidance on Ventilation for Gas Appliances is provided by B S 6644 2005 FLUE To ensure safe and satisfactory operation the chimney system which may be individual or common in the case of modular boiler installations shall be capable of the complete evacuation of combustion products at all times The effective height of the chimney terminal s above the boiler s flue outlet s shall ensure sufficient buoyancy to overcome the resistance of the bends tees and runs of the flue pipe involved and shall terminate in a down draught free zone The number of bends used should be kept to a minimum and flue runs should not be less than 45 to a horizontal should be avoided in order to comply with the recommendations made in BS 6644 2005 British Gas Publication IM 11 Flues for Commercial and Industrial Gas fired Boilers and Air Heaters The third edition of the 1956 Clean Air Act Memorandum and the Building Regulations should be strictly observed and approval obtained where applicable The chimney design should avoid the formation of condensate which may be achieved by insulating the flue The flue system must be designed to work specifically to remove the products of combustion IMPORTANT 90 square bends must not be used on the flue system 2 x 45 bends or easy sweep pattern should be used A minimum of 600mm straight vertical flue should be taken off the boiler flue outlet prior to any fittings FLUE SIZE CONSIDERATIONS Nomi
64. rols the safe start up of the burner in sequence See Fault Finding table on Page 36 for details of control box lockout conditions SECTION 4 PAGE 36 Fault Finding Stage 1 Boiler does not attempt to light Control Box does not lockout Stage 2 No Ignition Spark Pilot does not Light Control Box goes to lockout Stage 3 Ignition sparks Pilot does not Light Control Box goes to lockout Stage 4 Pilot Burner lights Control Box goes to lockout safety time Stage 5 Pilot Burner Lights Main burner does not light Control Box does not lockout Stage 6 Pilot Burner Lights Main burner lights Control box locks out POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS Check electricity supply is available to boiler and on off switch is illuminated The boiler has an integral fuse Check the boiler is being called to operate Thermostat calling lamp should be lit unless internal thermostat is satisfied or external control circuit is broken Check overheat cut off device has not operated Check power supply is available to control box see wiring diagram Replace box if faulty Check ignition electrode continuity for earth fault Check power supply is available to ignitor during ignition period Check operation of ignitor Replace if necessary Check gas supply is available at the pilot burner at the correct pressure Check gas supply is purged of
65. se the affected area with water and wash gently in the case of eye contact flush abundantly with water if irritation persists seek medical advice 3 Adhesive Wear gloves overalls in the case of an irritation rinse the affected area with water and wash gently in the case of eye contact flush abundantly with water and if irritation persists seek medical advice Inhalation continued exposure should be prevented 4 Sealing Rope Wear gloves overalls in the case of an irritation rinse the affected area with water and wash gently in the case of eye contact flush abundantly with water and if irritation persists seek medical 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 Site access available for persons carrying out the proposed work l oite Managers Personnel aware that work will be taking place III Risk Assessments carried out on possible risks which may effect the persons carrying out the proposed work IV Sections and fittings boxes were applicable should be positioned adjacent to the plinth s SECTION 4 PAGE 11 within the boiler house prior to persons carrying out the proposed work attending site As this will eliminate one source of on site injury taking place if this is unable to be done notice prior to attending site shou
66. sed air or soft brush and vacuum On no account should the burners be wire brushed 8 Remove the boller top panel by loosening the rear locking plate and pushing the panel towards the back 9 Remove the top Insulation and unscrew the flue box top cover for access to the heat exchanger 10 With the flue brushes provided clean the flueways of the cast iron heat exchanger if necessary The burner must be removed before cleaning Following completion remove the debris from the bottom of the boiler and clean around the boiler 11 Following completion of the above the boiler should be reassembled The integrity of the gaskets and insulation should be checked and replaced if necessary during reassembly 12 After reassembly test for gas soundness as detailed under commissioning and check the burner manifold union and pilot burner union for gas leaks FAULT FINDING Set out below are general guidance notes on system fault finding Overheat Operation Operation of the boiler overheat thermostat is associated with a reduction in boiler water flow Where overheat operation is reported the following should be checked a The boiler system pump has not tripped b Pump overrun is operational to dissipate residual heat from the boiler on system shut down c System valves are open d The boiler is operating at the correct rate and is not overfired To reset the overheat thermostat allow the boiler to cool down remove th
67. t 1 ft 28 32 litre 1 litre 0 03531 ft AREA 0 00155 in 6 452 cm 0 155 in 929 cm 1550 in 0 0929 m 10 76 ft FLOW RATE 1 gall min 2 0 7577 lit sec 1 lit sec 13 2 gall min 1 kg sec 1 lit sec 0 C 1 ft min 0 4719 lit sec 1 lit sec 2 119 ft min Reference temperature 1 ft min 0 00047 m sec 1 m sec 2119 ft min TEMPERATURE F to C X F 32 x 0 5556 C to F X C x 1 8 32 TEMPERATURE DIFFERENCE X F x 0 5556 C KU x 1 8 F 1 1 K WEIGHT 0 4536 kg 1 kg 2 205 Ib 50 8 kg 1 tonne 0 9842 ton 1016 kg 1 tonne 2204 6 Ib Commercial sales technical 8 service enguiries Tel 0845 0 0 1055 Fax 0845 0 0 1059 Sales hotline 0845 0 0 1056 0845 070 1057 0845 070 1058 Technical helpline Service hotline e mail potterton commercial baxigroup com web www pottertoncommercial co uk Spares Potterton Commercial spares are available nationwide through the interpart network of approved stockists Alternatively please contact Interpart Brooks House Coventry Road Warwick CV34 ALL Tel 0844 871 1540 BAXI GROUP Applications amp Installations Our experienced technical support team are available to offer advice on any aspect of heating system design and boiler installation Please contact 0845 0 0 1057 Commercial service offices Our service organisation covers the whole of the UK to look after your needs for all Potterton C
68. t the end sections should be positioned on the base as shown in Fig 17 Fig 17 150mm Minimum lt POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 15 Fitting of Flue Hood and Burners Fit the rear panel of the casing before the flue hood The flue hood is fitted onto the top of the boiler block and a seal must be made using the ceramic felt provided between the sections and the flue hood Take the roll of ceramic felt packed with the boiler and cut a strip and flue it across the front end of the sections Next cut two pieces of sealing strip to form the side seal 1 on top of each end section see Fig 18 Finally add the rear sealing strip This sealing strip does not sit on the top of the end sections but underneath the lip at the back of each section Fix the hood using the clamping plates K Fig 18 Ensure that there is a good seal made between the back of the heat exchanger block and flue hood See Page 21 for handling the gas manifold FITTING OF BURNER ASSEMBLY 17 to 22 SECTION Stage 1 Fold the pieces of insulation as Figure No 1 and then fit the pieces of insulation firmly in between the sections legs at the rear of the boiler See Figure No 2 1 2 Stage 2 Clean the base tray mounting seat and fix the sealing strip with the adhesive provided See Figures 3 4 SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPER
69. t Exchanger Rear Plate 15 Section _ Heat Exchanger Rear Plate 16 Section __ Heat Exchanger Rear Plate 17 Section Heat Exchanger Rear Plate 18 Section Heat Exchanger Rear Plate 20 Section Heat Exchanger Rear Plate 22 Section lt Retaining Clip Rear Insulation 10 Section 1 11 Rear Insulation 11 Section Z S Rear Insulation 12 Section 1 1 gt Rearlnsulation 13 Section 1 MEN MEN ami mmm 2 Rear Insulation 14 Section Rear Insulation 15 Section Rear Insulation 16 Section Rear Insulation 17 Section POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 6 INSTALLATON OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 43 No __ Rear Insulation 20 Section 136759 __ Rear Insulation 22 Section TI 15196760 Tie Rod M10x775 10Secton COMN9171030 Tie Rod M10 x 855 11 Section 2 COMN9171040 Tie Rod M10 x 935 12 Section 2 COMN9171050 Tie Rod M10 x 1015 13 Section _ _ 2 COMN9171180 Tie Rod M10 x 1100 14 Section 2 COMN9171250 Tie Rod M10 x 1180 15 Section 2 COMN9171260 Tie Rod M10 x 1260 16 Section 2 COMN9171270 Tie Rod M10 x 1340 17 Section 2 COMN9171280 Tie Rod M10 x 1420 18 Section 2 COMN9171290 Tie Rod M10 x 1585 20 Section 2 COMN9171470 Tie Rod M10 x 17
70. t exchanger and conveying it to the boiler room Each waterway section weighs approximately 40 Kg and measures 800mm x 500mm x 80mm Ensuring all Manual Handling Techniques are followed Particular attention must be paid to ensuring cleanliness of the boiler room and waterway sections dust or moisture may result in imperfect adhesion of the sealants which are applied during the erection of the waterways All tapped holes should be degreased before making connections POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS C O S H H During the erection procedure there are a number of items which are subject to the Control Of Substances Hazardous to Health C O S H H Regulations and may require specialist Personal Protective Equipment P P E beyond what is normally required Listed below are the items subject to the C O S H H Regulations and the recommended precautions that should be taken For a full breakdown of any substances listed below please contact the Commercial Technical Department 1 Refractory Ceramic Fibre Insulation Wear gloves overalls and safety glasses in the case of an irritation rinse the affected area with water and wash gently in the case of eye contact flush abundantly with water if irritation persists seek medical advice 2 High Temperature Glass Fibre Insulation Wear gloves overalls and safety glasses in the case of an irritation rin
71. the two screws securing the pilot burner to the burner mounting plate when removing the pilot burner take care not to loose the pilot injector 2 Release the electrodes and fit new electrodes if necessary 3 Fit the pilot burner and check the electrode position as shown in Fig 25 page 27 High Limit Control amp High Low Thermostat 1 Remove the two screws securing the control panel front fascia and hinge it down 2 Release the quick release connection on the door by firmly pressing in and turn it one quarter turn to the left to open the door 3 Remove the chain and earth wires and lift the door off 4 Remove the thermostat phial from the thermostat pocket and thread it through the grommet into the control panel o Remove the electrical connections to the thermostat which are made by push on female connectors 6 Remove the nut securing the thermostat to the control panel fascia For the control amp high low thermostats the nut is located beneath the thermostat knob and for the limit thermostat it is located beneath the cover N Fitting the new thermostat is the reversal of the above procedure The thermostat phial should be positioned as shown in Fig 21 page 24 SECTION 4 PAGE 37 Thermometer 1 Remove the two screws securing the control panel front fascia and hinge it down 2 Release the guick release connection on the door by firmly pressing in and turn it one guarter turn to the left to ope
72. tion Strips 13 Section 0000 _ Insulation Strips 14 Section 0000 __ Insulation Strips 15 Section 00000 __ Insulation Strips 16 Section o o Z o __ Insulation Strips 17 Section 00000 __ Insulation Strips 18 Section _ Z o __ Insulation Strips 20 Section 00 __ Insulation Strips 22 Section __ Vertical Insulation Stip AllModels o Gas Manifold 10 Section p NEN MEN pe NEN NEN png ZEE o p NC AN MEE Gas Manifold 11 Section SECTION 6 POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 46 DERWENT PRESTIGE PLUS Item Description Ouantity Part No No 8A Union Gasket 1 9 to 11 Section Not Shown 8 Union 1 9to 11 Section S15922350 Union 1 12 to 22 Section 8A Union Gasket 1 17 12 to 22 Section Not Shown 9 5 M M NET Pressure Test Point 1 8 Securing Nut 8x50 1 11 oight Glass Assembly 2 E 6 p i KO po LEES Pilot Tube 9 to 12 Section o Z 1 1 O Pilot Tube 13 to 15 Section 1 Pilot Tube 16 to t8Secion 1 O Pilot Tube 20 amp 22Section t O C NENNEN po p jk M ae KRETI KU CE 0 pm pt EAE Pilot Mounting Plate Pilot Assembly Ignition Electrode lonisation Electrode Ji poi NN 1 8 Pilot Tube Elbows Pilot Injector 0 5 Natural Gas Pilot Injector 0 25 LPG 9 Pilot Su
73. tion should be made to the female connection size given in Table 2 page 1 A union and isolating valve should be fitted close to the boiler to allow disconnection of the boiler controls for maintenance and repair The gas supply should be made through a suitable meter and the local gas undertaking should be consulted to determine the suitability of the meter and the gas supply to meet existing and additional demands for gas The installation shall be made in accordance with the requirements of the Gas Safety Installation amp Use regulations and all other Regulations and Codes of Practice given on page 6 In particular before connecting the boiler ensure that the gas supply has been purged of air and a manual valve for isolation of the boiler is fitted in an accessible position readily identifiable adjacent to the boiler Boiler Controls The operation of the boiler is under the control of its own control box boiler high low and overheat thermostats In addition the boiler should be controlled by a time switch frost thermostat pump overrun facility and for multiple boiler installations a boiler sequence controller The boiler can be controlled by removing POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS The gas supply should be supported adequately For large single and multiple boiler installations consideration should be given to the installation
74. tion should occur during commissioning or subsequent use of this product be it a fault of the boiler or of any instrument machine or service in the proximity of the burner then the GAS and ELECTRICITY supply to the burner should be IMMEDIATELEY ISOLATED until such time that the fault has been investigated and rectified IMPORTANT After each adjustment gas flow rate and flue gas analysis should be re checked POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS ALWAYS Use approved test eguipment Continually monitoring electronic eguipment is recommended NEVER rely on a visual inspection of the flame as a guide to combustion guality Following during commissioning of the burner unit the following additional checks should be carried out 1 Operation of the control high low and high limit thermostats should be checked for correct operation 2 The flue draught available at the appliance flue outlet should be checked under all operating conditions hot and cold and should be within the boiler operating parameters see Table 3 amp 4 pages 2 8 3 3 The fuel supply to the appliance should be isolated and the burner operated to ensure safety shut down and lockout of the burner on flame failure 4 Shut down of the boiler plant by external controls does not cause a hazardous condition and pump overrun is provided to remove residual heat from the boiler s Fo
75. ttempt to relight Check that the ignitor starts and that the boiler locks out SETTING THE GAS VALVE 9 to11 Section High Fire Setting 1 Start the burner with the two thermostats at maximum The boiler should warm up for a minimum of 20 minutes before starting setting procedure 2 The high fire setting has to be done first by turning the setting screw A of the gas valve governor Turn to the right for more pressure or left for less pressure on the burner manifold 3 Set the high fire pressure to 16 5 mbar Reduced Rate Setting 1 Reduce the setting of the high low thermostat to minimum so that the boiler goes to low fire POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS 2 Unlock the screw B on the solenoid valve head and turn to the low rate setting ring C turn clockwise for less pressure and anti clockwise for more pressure on the burner manifold 3 Set the low fire pressure to 10 6 mbar Fig 28 Dungs MB ZRDLE A Setting Screw of Governor B Locking Screw C Low Fire Adjustment Ring D Adjustment Cap SETTING THE GAS VALVE 12 TO 22 SECTION High Fire Setting 1 Start the burner with the two thermostats at maximum the boiler should warm up for a minimum of 20 minutes before starting setting procedure 2 The high fire setting has to be done first by turning the setting screw behind the protecting head of the governor I
76. turn cannot be on the same side of the boiler Combustion Chamber Front Plate Bond the silicone rubber foam strips to the right and left hand sections of the heat exchanger delivered unassembled and bolt to the front plate U to these sections Fig 16 Use the nuts and washers supplied Put an insulating sealing strip on the front fold of the base plate The base plate is not screwed to the front plate U of the burner Gas Train The gas train X is delivered assembled and prewired to be fitted to the right or left It is connected to the connector on the gas burner manifold by a union Y Fig 18 Remove the cap from the appropriate connector Y and tighten the free part of the union using a flat washer to seal the joint Fit the pilot light assembly to the appropriate side Z or Z this MUST be fitted on the same side of the burner plate as the gas train Fit the pilot light supply tube For connection see Gas Supply Handing Flow 8 Return On the 20 and 22 section boilers the flow and return connections must not be made on the same side of the boiler they MUST be diagonally opposite On the 12 to 22 section boilers the return and the Gas Train cannot be on the same side DERWENT PRESTIGE PLUS Fig 18 POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 19 ASSEMBLY OF CASING 9 to 22 section A Fit the right and left sides
77. ue Box 20 Section Flue Box 22 Section _ Flue Box Top Cover 10 Section _ Flue Box Top Cover 11 Section _ Flue Box Top Cover 12 Section _ Flue Box Top Cover 13 Section _ Flue Box Top Cover 14 Section _ Flue Box Top Cover 15 Section __ Flue Box Top Cover 16 Section __ Flue Box Top Cover 17 Section _ Flue Box Top Cover 18 Section _ Flue Box Top Cover 20 Section p Flue Box Top Cover 22 Section POTIERTON COMMERCIAL PRODUCTS DIVISION SECTION 6 INSTALLATON OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS PAGE 51 N O 3 4 5 7 S Pack of Securing Screws 000000000 4 Flue Cover Insulation 9 Section __ Flue Cover Insulation 10 Section __ Flue Cover Insulation 11 Section __ Flue Cover Insulation 12 Section __ Flue Cover Insulation 13 Section __ Flue Cover Insulation 14 Section __ Flue Cover Insulation 15 Section NEEN HEN NEN p La 6 NE a 9903295 17070907 17070908 17070909 17070910 17070911 17070912 17070913 17070914 17070915 17070916 17070917 17070918 9900540 9136917 COMN9205320 SECTION 6 POTIERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 52 DERWENT PRESTIGE PLUS Fig 38 Control Panel No __ Complete Control
78. ure a safe installation and working environment Regardless of the type of activity being assessed the principles of risk assessments are the same The basic steps are Classify Activity Identify Hazards Identify Existing Control Measures Determine Risk Assess Acceptability of Risk Prepare a Control Plan Implement Plan Review Plan Record Results Manual Handling Any person or persons moving or lifting the boiler or any part of the boiler should be trained in Manual Handling Technigues and if necessary use suitable lifting eguipment to reduce the risk of injury to themselves and other people Personal Protective Eguipment When undertaken any work you must comply with the Personal Protective Eguipment Regulations 1992 Confined Spaces A confined space as defined in the Health and Safety Confined Spaces Regulations 1997 means any place including any chamber tank vat silo pit trench pipe sewer flue well or other similar space in which by virtue of its enclosed nature there arises a reasonably foreseeable specified risk Precautions should be taken in all areas where by virtue of its even partially enclosed nature pose a reasonably foreseeable specified risk POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL DERWENT PRESTIGE PLUS Electrical Safety Working on appliances can be broken down to two main systems of work 1 Safe systems of work are adapted

Derwent Prestige Plus Installation Guide

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