Potterton Derwent Compact Plus Installation, Operation & Maintenance Manual
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Potterton Derwent Compact Plus Installation, Operation & Maintenance Manual

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MAY 2004

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Summary of Contents for Potterton Derwent Compact Plus

  • Page 1 MAY 2004...
  • Page 2 Hydraulic Test of Boiler - connecting the Water System 10 - condensate - connecting the Electrical Supply - connecting the Flue - connecting the Gas Supply - boiler Controls Section 5 Potterton Commercial Customer Commissioning Check List - contravention of regulations - commissioning...
  • Page 3 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS – CONDENSING PAGE 1 Fig 1 – General Data and Dimensions ØF Flow Return Table 1 – Boiler Dimensions Size ØF Return Flow 1200 1050 1150 1130 1 ¼”...
  • Page 4 SECTION 1 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 2 DERWENT COMPACT PLUS – CONDENSING Table 3 – Technical Data Model: Derwent Compact Plus Condensing 4/55 6/90 8/125 Number of Sections CE Certification Number 0063B03166 Gas Category...
  • Page 5 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS – CONDENSING PAGE 3 Fig- 2 – Steel Base Strip Details – (see section 2 – Boiler Siting and Base) Centre Line Of Boiler FRONT OF BOILER The boiler feet MUST NEVER be fixed in position (this is to allow for expansion).

  • Page 6: Installation

    Star efficiency and have Class 5 NOx. Any person installing or working on the boiler must be The Derwent Compact Plus Condensing is suitable for qualified and attention is drawn to the mandatory use on fully pumped open vented systems or a sealed requirements of CORGI.
  • Page 7 The Derwent Compact Plus Condensing is designed to be installed directly on the boiler house floor provided it is adequate but we would recommend that...
  • Page 8 SECTION 3 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 6 DERWENT COMPACT PLUS - CONDENSING VENTILATION are for guidance only and Potterton Commercial Division cannot accept responsibility for any flue Safe, efficient trouble free operation system designs.

  • Page 9: Boiler Protection

    Aluminium components a pH above 8.4 can cause failure of the Aluminium. The water system Potterton Commercial boilers are suitable for use on must be free of leaks to prevent raw water make up, sealed systems designed in accordance with BS which will dilute any inhibitors, promote corrosion and 6644: 1991 and BS 6880 Part 2.

  • Page 10: Boiler Installation

    SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 8 DERWENT COMPACT PLUS - CONDENSING BOILER INSTALLATION Safe systems of work are adapted for all boiler A Lifetime Guarantee is available on this boiler when maintenance & repair work undertaken on site.
  • Page 11 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS – CONDENSING PAGE 9 water and wash gently, in the case of eye contact, 10 Clear instructions supplied to the persons carrying flush abundantly with water, if irritation persists out the proposed work regarding positioning the seek medical advice.
  • Page 12 The flow and return connections are made at the rear of the boiler. Condensate Working Principles of the Derwent Compact Plus Condensing The condensate siphon of the secondary heat exchanger is at the rear of the boiler. It is only...
  • Page 13 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS – CONDENSING PAGE 11 etc.). It must be possible for the condensate to drain freely into a funnel. A trap must be installed between For large single and multiple boiler installations the funnel and sewer system.
  • Page 14 Commissioning should only be carried out by commissioning of a boiler takes place. personnel approved and competent to do so. This facility is available from Potterton Commercial Service Site access available for persons carrying out Offices at the addresses as listed on the back page of the proposed work.
  • Page 15 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 with the boiler at high fire and a flow temperature of 80°C.
  • Page 16 SECTION 5 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 14 DERWENT COMPACT PLUS - CONDENSING Control Panel 6. On/Off Switch 7. Override button for Safety Checks 8. Override Thermostat (Set fully right((maximum position)) allowing control by the 1...
  • Page 17 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 15 DERWENT COMPACT PLUS - CONDENSING burner manifold pressure the following procedure should be followed: Loosen the screw on the burner manifold and connect a manometer and check the...
  • Page 18 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 16 DERWENT COMPACT PLUS - CONDENSING the right damper positioning. product, be it a fault of the boiler or of any instrument, machine or service in the proximity of the burner then...
  • Page 19 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS - CONDENSING PAGE 17 and not on pump overrun if the boiler has been fired blue and well defined ‘V’ shaped flame. Then previously. check the main gas manifold gas pressure and...
  • Page 20 (Confederation Registered Installers) registration of personnel undertaking work on these appliances. This facility is available from Potterton Commercial Division, details are available from Regional Offices listed on the back page back of this manual. Boilers should be serviced and re-commissioned as a...
  • Page 21 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS - CONDENSING PAGE 19 system, if fitted, is operating correctly. 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.
  • Page 22 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 20 DERWENT COMPACT PLUS - CONDENSING On no account should the burners be wire brushed. After re-assembly test for gas soundness as detailed under Commissioning and check the burner manifold union and pilot burner union for gas leaks.

  • Page 23: Water Flow Switch

    If the control box lockout 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 Division service offices at the addresses on the back page of this manual.
  • Page 24 SECTION 5 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 22 DERWENT COMPACT PLUS - CONDENSING Fault Finding Stage 1 a) Check electricity supply is available to boiler and mains LED is illuminated. Boiler does not attempt to light.
  • Page 25 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS - CONDENSING PAGE 23 Stage 6 a) Check main burner gas valve is open. Pilot burner lights. b) Check electrical continuity to main gas valve. Main burner does not light.
  • Page 26 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 6 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS - CONDENSING PAGE 23 Safety burner thermostat DGAI Burner control system Flue thermostat Overheat thermostat Burner reset Burner test switch Rheostat Fuse Overheat indicator light Flame failure indicator light...
  • Page 27 SECTION 6 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 24 DERWENT COMPACT PLUS - CONDENSING...
  • Page 28 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 7 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS - CONDENSING PAGE 25 Spare Parts List - Casing Item No. Description Part No Left hand side panel assembly S137730A Right hand side panel assembly S137731A...
  • Page 29 SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 26 DERWENT COMPACT PLUS - CONDENSING Item No. Description Part No Condensor casing front panel insulation (6 sections) S137739 Condensor casing front panel insulation (8 sections) S137740 Condensor casing front panel insulation (4 sections)
  • Page 30 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 7 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS - CONDENSING PAGE 27 Heat Exchanger Assembly 48 Bag of Fixings Item No. Description Part No Left Hand Section S17800857 Right Hand Section S17800847 Intermediate Section...
  • Page 31 SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 28 DERWENT COMPACT PLUS - CONDENSING Insulation Strip (8 Sections) S132564 Insulation Strip (6 Sections) S132566 Insulation Strip (4 Sections) S132568 Thermostat Pocket S17001781 Spring Ref. 556557 S17006459 Cap No.290 ¼”...
  • Page 32 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 7 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS - CONDENSING PAGE 29 Fan Assembly 18 Silicon Tube Ø5/8 19 Screw Fixings Item Description Part No Connecting Piece for Fan (4-6 Sections) S137526 Connecting Piece for Fan (8 Sections)
  • Page 33 SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 30 DERWENT COMPACT PLUS - CONDENSING Flue Box Assembly 4 Section 6 & 8 Section 6 & 8 Section Item Description Part No Welded Flue Box Assembly (6 Sections)
  • Page 34 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 7 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS - CONDENSING PAGE 31 General Item Description Part No Ceramic Felt Seal 20 x 3 SN9205320 Flue Securing Plate 30 x 40 SN9180060 Wing Nut M8 x 20...
  • Page 35 SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 32 DERWENT COMPACT PLUS - CONDENSING Burner Bar Assembly 1 Burner Bar Assembly 24 Pilot Assembly 34 Gas Supply Pipe Assembly Item No. Description Part No 1 (not...
  • Page 36 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 7 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS - CONDENSING PAGE 33 Gas Valve Honeywell VR46011QB2019 S502834 Adapter Screw 45.900.428-003 S503173 Gas Valve Honeywell VR4605CB1009 (6-8 Sections) S500433 Honeywell Wiring Assembly S132391 Gas Valve Tube (4 Sections)
  • Page 37 SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL PAGE 34 DERWENT COMPACT PLUS - CONDENSING Control Panel Item No. Description Part No Front Panel S137535 Counter Mask FMG-GMG S17002268 Thermometer Mask R3 S17002281 Rear Panel S137874A Bolt DZUS...

  • Page 38: Commissioning Report

    COMMISSIONING REPORT REPORT SENT TO INSTALLER: DATE: Brooks House, Coventry Road, Warwick, CV34 4LL. SIGNATURE: Tel: (08706) 050607 Fax: (08706) 001516 REPORT No: INSTALLER NAME & ADDRESS: SITE ADDRESS: COMMISSIONING DATE: BOILER COMBUSTION Pilot High Unit Type: Inlet Gas Supply Pressure mbar No.
  • Page 39 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 on the back page of this manual.

  • Page 40: Conversion Table

    CONVERSION TABLE IMPERIAL TO METRIC METRIC TO IMPERIAL HEAT 1 Btu/hr = 0.291 W 1 kW = 3412Btu/hr 1 Therm = 100,000 Btu/hr 1 Btu = 1055 J = 0.0009478 Btu 1 Btu/hr = 0.252 kcal/hr 1 kcal/hr = 3.968 Btu/hr = 28.317 dm FUEL CONSUMPTION 1 ft...
  • Page 41 Commercial Sales Commercial Service Technical and Service Enquiries Our service organisation covers the whole of the UK to look after your needs for all Potterton Commercial Potterton Commercial products. We are also able to offer our services for other manufacturers products.

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