Potterton mersey super Installation And Service Instructions Manual
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Potterton mersey super Installation And Service Instructions Manual

Potterton mersey super Installation And Service Instructions Manual

Non spouted multipoint model
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Mersey Super - Installation & Service Instructions
Page 1 of 35
INSTALLATION AND SERVICE INSTRUCTIONS
Mersey Super
Gas Fired Water Heater
G.C. NO.52476 38
NON SPOUTED MULTIPOINT MODEL
FOR USE WITH NATURAL GAS
THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1984.
"In your own interest, and that of safety, it is law that all gas appliances are installed by
competent persons, in accordance with the above regulations. Failure to install appliances
correctly could lead to prosecution."
Installation must be in accordance with the Building Regulations, Byelaws of the Water
Undertaking, and I.E.E. Wiring Regulations. It should be in accordance also with any
relevant requirements of the Local Gas Region and Local Authority and the relevant
recommendations of the following British Standard Codes of practice: BS 6891, BS
5440:1:2 and BS 5546.
LEAVE THESE INSTRUCTIONS WITH THE USER FOR USE ON FUTURE CALLS
file://P:\System\DATA\Dx\DS1\installation\2551\I24-2551\I24-2551.htm
09/12/2009

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  • Page 1 Mersey Super - Installation & Service Instructions Page 1 of 35 INSTALLATION AND SERVICE INSTRUCTIONS Mersey Super Gas Fired Water Heater G.C. NO.52476 38 NON SPOUTED MULTIPOINT MODEL FOR USE WITH NATURAL GAS THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1984.

  • Page 2: Energy Cut-Off Device

    Page VENTILATION Being a room sealed appliance, the Mersey Super does not require an air vent in the room or space in which it is installed. Where this appliance is installed in a compartment, air vents to the compartment at both high and low levels, should be provided for cooling.

  • Page 3: Technical Specifications

    Mersey Super - Installation & Service Instructions Page 3 of 35 42 in² 42 in² In compartment which is ventilated to 137 cm² 137 cm² outside 21 in² 21 in² GENERAL IMPORTANT: The area of wall covered by the appliance must be flat.

  • Page 4: Minimum Clearances

    Mersey Super - Installation & Service Instructions Page 4 of 35 Pilot injector 0.27mm marking A Nominal burner pressure ** (maximum input) 12.5 mbar (5 in. w.g.) Connections - Gas 15mm Copper Tail - Water 15mm Compression Balanced flues (telescopic) Wall thickness...

  • Page 5: Installation

    Mersey Super - Installation & Service Instructions Page 5 of 35 Fig. 1 Page 3 3. INSTALLATION - Page 4 Fig. 2 A. LOCATION 1. If the appliance is to be fixed to a suitable existing terminal first isolate and remove the old appliance.
  • Page 6 Mersey Super - Installation & Service Instructions Page 6 of 35 NOTE: Where the appliance is to be installed into a SEDUCT the minimum duct required is 228mm (9in) deep, 349mm (15½ in) wide. Fig. 3 3. Where the building regulations require it, a flue terminal guard should be fitted symmetrically around the outer part of the flue terminal.

  • Page 7: Gas Connection

    Mersey Super - Installation & Service Instructions Page 7 of 35 8. Lift the appliance into position, locating the flue outlet into the circular duct on the flue terminal. 9. Secure with the appropriate nuts and washers. Fig. 5 B. GAS CONNECTION IMPORTANT: Blow out all foreign matter from the supply pipe before connecting to the gas service cock.
  • Page 8 Mersey Super - Installation & Service Instructions Page 8 of 35 Fig. 6 Page 5 INSTALLATION - Page 6 file://P:\System\DATA\Dx\DS1\installation\2551\I24-2551\I24-2551.htm 09/12/2009...

  • Page 9: Water Connections

    Mersey Super - Installation & Service Instructions Page 9 of 35 Fig. 7 C. WATER CONNECTIONS IMPORTANT: Flush out all foreign matterfrom the supply pipe before connecting to the service cock. 1. Assemble the filter, olive and inlet tail to the water inlet. NOTE: The inlet tail need not be used as a vertical supply can be routed directly onto the water inlet.

  • Page 10: Lint Filter

    Mersey Super - Installation & Service Instructions Page 10 of 35 Fig. 8 D. LINT FILTER This appliance has a lint filter fitted around the base of the pilot tube. Ensure that the filter gauze is located inside both end caps and that the complete assembly is correctly seated over the union nut at the base of the pilot tube.

  • Page 11: Fault Finding

    Mersey Super - Installation & Service Instructions Page 11 of 35 2. Ensure that the gas and water supplies are turned ON. 3. Ensure that all hot water outlets are closed. 4. Remove the screw and sealing ring from the burner pressure test point and attach a pressure gauge.
  • Page 12 Mersey Super - Installation & Service Instructions Page 12 of 35 Fig. 11 Page 7 COMMISSIONING - Page 8 Fig. 12 NOTE: If a gas rate check is required, the gas consumption after 3 minutes running should be approximately 48.5 l/mm (1.7³/min).
  • Page 13 Mersey Super - Installation & Service Instructions Page 13 of 35 Fig. 13 Explain to the user how to operate the appliance. - see the "Instructions for Use" booklet. Show the user the position of the Identification Badge. HAND OVER THE "INSTRUCTIONS FOR USE" TO THE USER.
  • Page 14 Mersey Super - Installation & Service Instructions Page 14 of 35 The burner ignition has been factory set and should not need adjustment. However, if adjustment is required a slow ignition screw is fitted to the appliance and is situated above the cap screw in the water governor body (fig.
  • Page 15 Mersey Super - Installation & Service Instructions Page 15 of 35 6. Clean any deposits off the heating unit by washing or brushing. Descale the heating unit if required. Fig. 16 Page 9 6. REPLACEMENT OF PARTS - Page 10 IMPORTANT: THE FOLLOWING WORK SHOULD ONLY BE CARRIED OUT BY A COMPETENT SERVICE ENGINEER.

  • Page 16: Piezo Unit

    Mersey Super - Installation & Service Instructions Page 16 of 35 Page 10 REPLACEMENT OF PARTS - Page 11 6.1. PIEZO UNIT It will NOT be necessary to remove the outer case. file://P:\System\DATA\Dx\DS1\installation\2551\I24-2551\I24-2551.htm 09/12/2009...

  • Page 17: General Access/Main Burner

    Mersey Super - Installation & Service Instructions Page 17 of 35 a. Slide out the bottom cover. b. Disengage the electrode lead from the piezo unit. c. Remove or loosen and pull aside the spark button retainer, taking care not to lose the shakeproof washer.
  • Page 18 Mersey Super - Installation & Service Instructions Page 18 of 35 d. Remove 4 fixing screws from the burner assembly (2 each side). e. Remove 2 screws securing the front to the heating unit. f. Pull the burner assembly slightly forwards to clear the injectors, then pull apart and withdraw taking care not to snag the pilot assembly.

  • Page 19: Pilot Injector

    Mersey Super - Installation & Service Instructions Page 19 of 35 Fig. 20 6.3. THERMOCOUPLE AND SPARK ELECTRODE a. Gain general access -see 6.2. b. Remove the fixing screw and bracket then lower the spark electrode. c. Disconnect the nut securing the thermocouple to the interrupter at the chassis base.

  • Page 20: Flame Safety Device

    Mersey Super - Installation & Service Instructions Page 20 of 35 Fig. 22 6.5. FLAME SAFETY DEVICE a. Gain general access -see 6.2. b. Disengage the electrode lead from the piezo unit. c. Release the thermocouple from the back of the flame safety device.

  • Page 21: To Drain The Appliance

    Mersey Super - Installation & Service Instructions Page 21 of 35 Fig. 23 6.6. TO DRAIN THE APPLIANCE a. Ensure that the gas and water service cocks are turned OFF. b. Open a hot water outlet. c. Have a suitable container to hand . Remove the drain screw from the water service cock and allow the water to drain.
  • Page 22 Mersey Super - Installation & Service Instructions Page 22 of 35 Fig. 25 Page 13 REPLACEMENT OF PARTS - Page 14 Fig. 26 e. Remove 2 screws above the chassis base securing the governor to the automatic valve. f. Remove 3 screws above the chassis base securing the governor to the chassis base.
  • Page 23 Mersey Super - Installation & Service Instructions Page 23 of 35 Fig. 27 DESCALE AND REGREASE j. Remove both the brass washer and ‘O’ ring from the top opening. Clean the washer. k. Clean the top opening then pack with a silicone grease such as Dow Corning 111.

  • Page 24: Water Governor Venturi

    Mersey Super - Installation & Service Instructions Page 24 of 35 REPLACEMENT OF PARTS - Page 15 6.8. WATER GOVERNOR VENTURI a. Gain general access -see 6.2. b. Drain the appliance -see 6.6. c. Release the union nut and clamping plate then remove the feed pipe.
  • Page 25 Mersey Super - Installation & Service Instructions Page 25 of 35 Fig. 30 g. Re-fit the water governor. h. Re-connect the burner supply pipe. i. Test for gas soundness as follows:- - Ensure the water service cock is in the OFF position, this will ensure that water CANNOT flow and open the automatic valve.

  • Page 26: Heating Unit

    Mersey Super - Installation & Service Instructions Page 26 of 35 Page 15 REPLACEMENT OF PARTS - Page 16 Fig. 33 6.10. HEATING UNIT a. Gain general access -see 6.2. b. Drain the appliance -see 6.6. c. Remove the 2 screws securing the energy cut-off device to the heating unit (located top front left).

  • Page 27: Descaling The Heating Unit

    Mersey Super - Installation & Service Instructions Page 27 of 35 Fig. 33 6.11. DESCALING THE HEATING UNIT WARNING: ACID/WATER SOLUTION MUSTBE USED WITH EXTREME CAUTION. TAKE CARE NOT TO SPLASH ONTO SKIN OR INTO THE EYES. WASH ANY AFFECTED AREAS WITH LARGE AMOUNTS OF COLD WATER AND SEEK MEDICAL ADVICE.
  • Page 28 Mersey Super - Installation & Service Instructions Page 28 of 35 g. Adjust the pinch cock and allow the fluid to slowly pass through the heating unit into the collecting tank. h. Continue the process until the fluid ceases to bubble. It may be necessary to replenish the solution.

  • Page 29: Fault Finding

    Mersey Super - Installation & Service Instructions Page 29 of 35 Fig. 35 Page 17 7. FAULT FINDING - Page 18 SYMPTON POSSIBLE CAUSE SOLUTION PILOT WILL NOT LIGHT 1. Gas not turned on. 1. Turn on the gas at the service cock and/or the main gas line.
  • Page 30 Mersey Super - Installation & Service Instructions Page 30 of 35 located at the base of pilot tube. 8. Faulty components. 8. Replace any faulty components found. Piezo Unit - Part No 10/ 11935. Electrode Assembly - Part No 10/17493.
  • Page 31 Mersey Super - Installation & Service Instructions Page 31 of 35 10/17572. 4. Automatic gas valve push rod 4. Dismantle clean and jammed. May also cause a high regrease using Dow Corning water rate. 111 silicone grease. Handle the push rod with care, do not bend.
  • Page 32 Mersey Super - Installation & Service Instructions Page 32 of 35 3. Automatic gas valve push rod 3. Dismantle clean and sticking. May also cause a high regrease using Dow Corning water rate 111 silicone grease. Handle the push rod with care, do not bend.
  • Page 33 Mersey Super - Installation & Service Instructions Page 33 of 35 SYMPTOM POSSIBLE CAUSE SOLUTION 1. Faulty case or terminal seal. 1. Check that the outer case SMELL OF COMBUSTION seal - Part No 10/17501 and PRODUCTS terminal seal - Part No...
  • Page 34 Mersey Super - Installation & Service Instructions Page 34 of 35 Page 22 file://P:\System\DATA\Dx\DS1\installation\2551\I24-2551\I24-2551.htm 09/12/2009...

  • Page 35: Short Spare Parts List

    Mersey Super - Installation & Service Instructions Page 35 of 35 SHORT SPARE PARTS LIST - Page 22 Key No. G.C. Part Description. Makers Part Off. 284 957 Seal Pack - Chassis to Flue Terminal 31/12299 285 907 Case Assembly...

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