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Potterton Statesman System L Installation & Service Instructions Manual

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Installation & Service Instructions
About the Boiler
About Safety
This is a Floor Standing, Horizontally Fired, Automatic Pressure Jet Oil Boiler.
The boiler can be flued conventionaly or with a kit as a balanced flue.
This boiler is for use with Kerosine and for use in GB & IE.
This boiler can be converted for use with Gas Oil.
Installation must be in accordance with the Installation & Service Instructions and the rules in
force.
Leave these instructions with the user for use on future calls.
Statesman
System L,
Flowsure L, Flowsure + L

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  • Page 1 Installation & Service Instructions Statesman System L, Flowsure L, Flowsure + L About the Boiler This is a Floor Standing, Horizontally Fired, Automatic Pressure Jet Oil Boiler. The boiler can be flued conventionaly or with a kit as a balanced flue. This boiler is for use with Kerosine and for use in GB &...

  • Page 2: Table Of Contents

    Contents Section 1 - Technical Data..........4 Section 5 - Fault Finding...........44 Health & Safety Information........4 Burner does not start, motor does not run....44 System Components..........5 Burner starts, no flame established, no Boiler Wiring Diagrams..........9 oil to burner............44 Technical Data............12 Burner starts, no flame but oil to burner.....45 Boiler Dimensions &...
  • Page 3 WARNING ! - this is about YOUR safety Safe use of Kerosines and Gas Oils Hazards These fuels give off a flammable vapour when heated even moderately. This vapour ignites easily, burns fiercely and can be explosive. Vapour can flow along at ground level and collect as an explosive mixture in drains, cellars etc. at considerable distances from open containers or spillages.

  • Page 4: Section 1 - Technical Data

    1 - Technical Data • The Statesman boilers are horizontally fired, Flue Gas Sampling Point automatic pressure jet boilers. These boilers are intended for use on indirect central heating systems. To aid commissioning, a flue gas sampling point is Their use on direct systems is not recommended. built into the heat exchanger front access door.

  • Page 5: System Components

    Statesman System, Flowsure & Flowsure+ pressure domestic hot water. The domestic hot water temperature can be increased by reducing the water flow rate at the tap (Flowsure) or adjusting Principal boiler components the hot water mixing valve to a higher setting (Flowsure+).
  • Page 6 Statesman System Automatic Air Vent Conventional Flue Pump Pressure Relief Valve Thermostat Pocket Main Facia Panel Flow Control (22mm) Thermostat Thermostat Indictator Pocket Expansion Programmer Lights Vessel (Optional) Pressure and Burner Air Temperature Gauge Inlet Pipe Expansion Vessel Cradle Combustion Chamber Access Panel Lockout Combustion Chamber...
  • Page 7 Statesman Flowsure Conventional Flue Flow Switch Certain Items Removed For Clarity (Type 2) Manual Domestic Air Vent Service Automatic Cock Air Vent Pressure Relief Valve Flow Pump Switch Overrun Supplied (Type 1) Pocket Boiler Thermostat Cold Water Pocket Feed (15mm) D.H.W.
  • Page 8 Statesman Flowsure + Flow D.H.W. Flow Switch Switch Flow (Type 2) (Type 1) (15mm) NOT Supplied Cold Mixing Water Valve Certain Items Removed For Clarity Feed Conventional (15mm) Flue Automatic Domestic Air Vent Service Pressure Cock Relief Valve Plate Heat Exchanger Pump Overrun Pocket...

  • Page 9: Boiler Wiring Diagrams

    Boiler Wiring Diagram - Statesman System Pump Link to be replaced with Tray Assembly room thermostat Boiler Stat. Mains Burner Colour Coding Lockout For The Wiring - Blue Limit Stat. br - Brown Overheat Terminal gy - Grey Block - Red bl - Black Terminal g/y - Green/Yellow...
  • Page 10 Boiler Wiring Diagram - Statesman Flowsure Main Supply Tray Assembly Connection Diverter Valve Pump Live Earth Flow Switch Neutral 2 Position Switch Boiler Electro-mech. C.Heating Clock Boiler Stat. 3 Position Switch Mains LINK to be replaced Colour Coding with room thermostat Pump Overrun 21(6)
  • Page 11 Boiler Wiring Diagram - Statesman Flowsure + Main Supply Connection Tray Assembly Diverter Valve Live Pump Earth Flow Switch Neutral 2 Position Switch Boiler Tank Thermostat Electro-mech. C.Heating Clock Boiler Stat. 3 Position Switch Mains LINK to be replaced Colour Coding with room thermostat Pump 21(6)

  • Page 12: Technical Data

    Technical Data Model System 70/90 Flowsure 70/90 Flowsure+ 70/90 Btu/h Btu/h Btu/h 89,000 89,000 89,000 Maximum Output Minimum Output 68,000 68,000 68,000 Kerosene 79,000 79,000 79,000 Factory Set Output Riello Burner Type RDB1 RDB1 RDB1 Combustion Head Type Kerosene Gas Oil Nett Full Load Efficiency 91.0 91.0...

  • Page 13: Boiler Dimensions & Clearances

    Boiler Dimension & Clearances System Flowsure Flowsure+ Model Height Width Depth Centre of flue from rear Flue Diameter Height of bottom connection Distance of conn. from wall 1" B.S.P 1" B.S.P Return Connections 2off 1" B.S.P 1 off Flow connections 1 off 22mm 22mm...

  • Page 14: Flue Layouts

    Flue Options: Low Level Horizontal High Level Horizontal High Level Vertical Flue Kits 1, 2, 5, & 6 Flue Kits 3, 5, 6, 7, & 8 Flue Kits 3, 4, 5, 6, 9 & 10 Kits 1 & 2 Kits 7 & 8 Kit 4 Intersection Kits 5 &...

  • Page 15: Section 2 - Pre-Installation Requirements

    These books are available from OFTEC, Century House, 100 High Street, Banstead, Surrey SM7 2NN. Training Potterton have several training centres around the country, for details of courses for oil firing telephone 01926 430481. OFTEC also hold training courses on oil fired central heating.

  • Page 16: Chimneys/Flues

    Control of pollution (oil) regulations. • Local water undertakings bye-laws. Chimney Every Potterton boiler has a very high efficiency and care must be taken to ensure that the chimney is suitable. Chimneys may have been already built and completed before a choice of appliance has been made.

  • Page 17: Combustion & Ventilation Air Requirements

    Internal Flues c) For the satisfactory operation of any draught break or stabilizer which may be fitted. The exposed flue pipe between the boiler flue off-take and the chimney proper (either internally or externally) Air for Combustion must not be of asbestos. Vitreous Cast Iron, Steel or similar materials should be used.

  • Page 18: Balanced & Low Level Terminal Clearances

    Extract Fans Draught Breaks If the room in which the appliance is located also has an When an appliance with a draught break is fitted in a room extract fan the performance of the appliance must be add 550mm /kW to the free area of the combustion air unaffected when the fan is running with all doors and inlet.
  • Page 19 Clearances Required Around Balanced and Low Level Discharge Flues Fitted to Oil Fired Boilers Likely flue positions requiring Fig. 13 a flue terminal guard Terminal Position with Minimum Distance (mm) A Directly below an opening, air brick, opening window Where the terminal is within 1 metre of any plastic material, such material should be B Horizontally to an opening, air brick, opening window protected from the effects of combustion...

  • Page 20: Oil Tanks & Layouts

    Tank Support Adequate safety may be achieved in a number of ways, for example: Steel tanks are normally supported on masonry piers. These have to maintain the tank at a sufficient height to a) Protecting the tank by a physical barrier or isolating enable access to be gained for painting.
  • Page 21 Storage Requirements and Tank Sizes end of the vent is fitted with a return bend and an open wire mesh balloon. Tanks are available in a wide variety of sizes and capacities. For boilers of up to 13 kW (45,000 Btu/h) A mushroom type vent may be fitted provided its free tanks with a capacity of 1200 litres (250 gallons) are area is at least equal to the cross sectional area of the...

  • Page 22: Floor Temperatures

    appliances with pressure jet burners by means of the building in the event of a fire starting up within the a single pipe need to be positioned so that they will boiler. apply the 300 mm minimum required head of oil to the burner when the fuel level is at its lowest point.
  • Page 23 The appliances incorporate a circulating pump, no other pump is required. The appliances will operate satisfactory on a two pipe small bore or micro bore system using thermostatically controlled radiator valves. When employing a central heating system where primary water flow may be prevented during a pump overrun situation (i.e.
  • Page 24 The automatic air vent automatically expels any air- Statesman Flowsure and Flowsure+ released from the water and thereby keeps the boiler fully charged. The final 600 mm of the mains cold water connection to the boiler should be made in copper tubing to BS Filling and Make-up Loop 2871 Pt 1, which is recommended for water carrying pipework and must be used for pipework carrying...
  • Page 25 Single Pipe Supply System Max. Oil Level 4 metres Above Burner Fire Valve Shut Off Sensor Valve Filter Fire Valve Max. Head 4m Pump Fire Valve De Aeration Sensor Device Fire Valve Oil Tank Below or Level Isolating with Burner Valve Oil Supply Pump...

  • Page 26: Section 3 - Installation & Commissioning

    3 - Installation & Commissioning Low Level Horizontal - Kits 1 & 2 High Level Vertical - Kits 3, 4, 9 & 10 With Extensions With Extensions Kit 5 Kit 4 Kit 4 950mm 1000mm 1000 to wall, to wall Kit 6 or chimney or chimney...

  • Page 27: Conventional Flue

    Installation & Commissioning It is possible to install the boiler without removing the casing sides but care should be taken not to damage the panels when connecting the water pipes. Fitting a Balanced Flue Refer to the Instructions supplied with the flue. Fitting a Conventional Flue Local Building Regulations and Bye Laws should be consulted for details of the chimney, use a 135°...

  • Page 28: Fuel Pipes

    Wiring Diagrams: Refer to wiring diagrams in Section 1 of these Instructions. The mains inlet plug is provided in the bag of fittings supplied. Control Box Note: A permanent live supply must be made, Assembly to allow the pump overrun device, as fitted to Remove the Flowsure and Flowsure+, to operate correctly.
  • Page 29 Fig. 21 Installation & Commissioning Part No. 5106463...
  • Page 30 Wiring Diagram - External Controls Statesman Flowsure, Flowsure + Detail With Room Stat/Frost Stat Room Stat Or Programmable Stat. Frost Stat * Flowsure Only gy * Clock Electro-mech. Remove Link COLOUR CODING b = Blue br = Brown gy = Grey w = White y = Yellow o = Orange...

  • Page 31: Water Connections

    An Isolation Valve should be placed on the tank side Statesman Flowsure+: of the filter, so that the oil supply can be isolated when A flow connection is provided at high level at the top servicing is required. rear of the boiler and one return connection is provided at low level to the left side of the boiler.
  • Page 32 Fig. 23 Installation & Commissioning Part No. 5106463...

  • Page 33: Commissioning

    Commissioning Continuous failure to light is almost certainly due to air remaining in the fuel supply. It is strongly recommended that the boiler/burner is 9. Start and stop the burner two or three times until commissioned by a qualified technician, preferably the flame cuts off sharply - this indicates any OFTEC trained and registered.
  • Page 34 4. Having completed the necessary water connections, If the pressure indicated on the pressure gauge is those connections not utilised should be plugged. greater than 2.5 bar when operating at the maximum 5. Check that the central heating system has been fully central heating temperature, an extra expansion vessel flushed out at installation using a flushing agent.
  • Page 35 Remove The 3 Retarders, Examine For Front Access Damage, Replace if Necessary Door Lift Out The Plate With This Hole Baffle Plate Remove Boiler Shell The Baffle Plate & Examine For Damage, Replace If Necessary Cover Thermostat Pocket Examine The Interior Of The Flue Burner...

  • Page 36: Section 4 - Servicing & Maintenance

    4 - Servicing & Maintenance • If the balanced flue is dismantled for any reason and • Examine interior of boiler and if necessary clean. the flue seals disturbed, new seals must be fitted. Remove any loose debris from the combustion Refer to the Parts Catalogue for part numbers.

  • Page 37: Replacement Of Parts

    for more than one heating season, a Sight replacement should be fitted. If a metal fine Gauge microbic filter is fitted then this should be cleaned with kerosene. Ensure that the filter Isolating bowl is thoroughly cleaned out before Valve replacement.

  • Page 38: Thermostats - Statesman System

    Replacement of Thermostats Lift Off The (Statesman System) Remove Facia & Sensor Replacing Disconnect 1. Remove the front cover. From The Indicator Thermostats 2. Pull off the temperature control knob. Pocket Lights Plug (Front Access) 3. If a clock is fitted un-clip from the facia and disconnect the plug at the back.

  • Page 39: Thermostats - Statesman Flowsure/Flowsure

    Replacement of Thermostats DHW Overheat Thermostat (Flowsure) (Flowsure/Flowsure+) 1. Disconnect the electrical connections. 1. Remove the front and top covers. 2. Unscrew the two screws securing the 2. Pull off the temperature control knob. thermostat to the controls assembly. 3. Un-clip the programmer assembly and push into the 3.

  • Page 40: Pressure Relief Valve

    Pressure Relief Valve 5. Un-clip the temperature/pressure gauge from its bracket, remove gauge, carefully withdrawing 1. Drain the boiler using the boiler drain point provided. sensor and bulb capillary tubes through bracket 2. Undo the compression fitting connecting the assembly. discharge pipe to the relief valve.

  • Page 41: Domestic Service Cock

    Domestic Service Cock (Flowsure/Flowsure+) Flowsure+: 1. Undo both nuts retaining the mixer valve and flow 1. Close the mains water isolation valve to boiler. switch assembly to the plate heat exchanger. 2. Drain the residual water from the hot water Remove assembly, and place aside, ensuring pipework.
  • Page 42 Inside Electrical Supplied Connector (6 way) Flow Switch (Type 2) Rear Electrical Connector (6 way) Flow Switch (Type 1) Plate Heat Exchanger Domestic Service Cock Controls Assembly Plate Heat Automatic Exchanger Air Vent Flue Spigot Pressure Sensor Flow Switch (Type 1) Pump Overrun DHW Limit...
  • Page 43 Rear Electrical Inside Electrical Connector Connector (6 way) (6 way) Primary Certain Items Removed For Clarity Water Heatstore Plate Heat Exchanger Flow Switch Controls Assembly (Type 2) Domestic Automatic Service Air Vent Cock Flow Flue Pressure Switch Spigot Relief Valve (Type 1) Limit Tank...

  • Page 44: Section 5 - Fault Finding

    5 - Fault Finding SYMPTOM CHECK LIST ACTION Burner Does Not 1. Mains switched on Switch on Start, Motor Does 2. Fuse in switch Fit a fuse Not Run 3. Fuse blown Replace fuse 4. All external controls call for heat Set to call for heat 5.

  • Page 45: Burner Starts, No Flame But Oil To Burner

    SYMPTOM CHECK FOR ACTION Burner Starts, 1. Signs of fuel in boiler Check as for 2 to 8 below No Flame But 2. Correct combustion head settings Set correctly refer to Burner Oil To Burner Instructions 3. Electrodes clean and not damaged Clean 4.

  • Page 46: Flame Established But Not Maintained

    SYMPTOM CHECK FOR ACTION Flame Established 1. Air in fuel line Check for joints for increases of air rectify as necessary, bleed burner But Not and restart Maintained 2. Combustion settings incorrect Adjust settings and confirm by flue gas analysis 3.

  • Page 47: Other Problems

    SYMPTOM POSSIBLE CAUSE ACTION 13. Bad oil cut off Bleed air from pump or replace pump assembly 14. Dirt collecting on fan Remove burner and clean 15. Combustion products leaking Check all joints, replace suspect seals SYMPTOM POSSIBLE CAUSE ACTION 1.

  • Page 48: Section 6 - Spare Parts

    6 - Short Spares Drg. Description Model - see key Makers Part Ref. Number Boiler thermostat E, F, G 26009018 Thermostat knob E, F, G 26002014 Limit thermostat E, F, G 26009097 Mains inlet plug E, F, G 26009004 Retarder E, F, G 26001335 Baffle Plate...
  • Page 49 (System Flowsure Flowsure +) Not Spared 28 / 29 Fig. 33 Spare Parts Part No. 5106463...

  • Page 50: Section 7 - Flue Kit Options

    7 - Flue Kit Options Dress Plate KIT 1 Fasteners Pack Horizontal Low Level Telescopic Instructions (Inner Wall) 4 - wood screws (Short Wall) 100 - 275mm 4 - wall plugs Inner Seal Outer Seal Dress Plate (Outer Wall) Gasket KIT 2 Horizontal Low Level Telescopic Fasteners Pack...
  • Page 51 Kit 5 Kit 4 Horizontal and Vertical Vertical Flue Extension Through 950mm Inner Seal Roof Outer Seal Terminal Kit 6 Horizontal and Vertical Flue Extension Inner Seal 300mm Outer Seal Clamping Plate Kit 7 Horizontal High Level Telescopic (Short Wall) Inner Seal 100 - 275mm Outer Seal...
  • Page 52 All goods are sold subject to our standard Conditions of Sale which are available on request. Baxi Potterton Brownedge Road, Bamber Bridge Preston, Lancashire PR5 6SN www.potterton.co.uk...

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