Potterton LPG 100e Installation And Servicing Instructions
Fanned
balanced flue gas fired boilers
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- Installation and servicing instructions (29 pages) ,
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Summary of Contents for Potterton LPG 100e
- Page 1 LPG 50e, 60e, 80e & 100e fanned balanced flue gas fired boilers THIS APPLIANCE IS FOR USE WITH PROPANE GAS ONLY Installation and Servicing Instructions LEAVE THESE INSTRUCTIONS ADJACENT TO THE APPLIANCE...
- Page 2 (e.g. flue dampers, economisers, etc.) be directly connected to these appliances unless covered by these installation instructions or otherwise recommended in writing. Any direct connection of a control device not approved by Potterton could invalidate the normal warranty. LIST OF CONTENTS - Page 2 General Page No.
- Page 3 OPTIONAL EXTRAS - Page 3 The following range of Potterton system controls are also ACCESSORIES available and further information will be provided on request. Thermostatic Radiator Valve Myson Electronic Cylinder Thermostat PTT2 Electronic Programmer E.P. 2001, E.P. 3001, E.P. Electronic Room Thermostat PRT2 4001, E.P.
- Page 4 SITE REQUIREMENTS - Page 4 FIG. 2 GENERAL ARRANGEMENT...
- Page 5 SITE REQUIREMENTS - Page 5 Where the installation of the boiler will be in an unusual 50mm (2 in) at the top (measured from the top of the boiler location, special procedures may be necessary and BS 6798 case), except where the optional extra pump cover is to be 1987 gives detailed guidance on this aspect.
- Page 6 SITE REQUIREMENTS - Page 6 MAXIMUM LENGTH ‘X’ 1 METRE FLUE SYSTEM 955mm 100e MODEL ONLY (37in) STANDARD FLUE SYSTEM 50e, 60e, & 80e 510mm MODELS ONLY (20in) 2 METRE FLUE SYSTEM 50e, 60e, & 80e 1955mm MODELS ONLY (77in) FIG.
- Page 7 TECHNICAL DATA - Page 7 BOILER INJECTOR GAS RATE at INPUT OUTPUT BURNER SUPPLY SIZE SIZE 95.0 MJ/m3 kW (Btu/h) kW (Btu/h) PRESSURE PRESSURE (2500 Btu/W) m3/h (W/h) mbar (in wg) mbar (in wg) 2.2mm 0.73 (25.8) 18.88 (64,400) 15.1 (51,500) 35.7 (14.3) 37 (14.8) 2.4mm...
- Page 8 TECHNICAL DATA - Page 8 The System SEALED SYSTEMS The boiler must be used on INDIRECT FULLY PUMPED Installation systems only, which may be sealed or open vented. The installation must comply with the requirements of The system should be designed so that the maximum BS 6798 1987 and BS 5449 Part 1.
- Page 9 TECHNICAL DATA - Page 9 If the system is extended, the expansion vessel volume may Method of Make-Up have to be increased unless previous provision has been made for the extension. Where a vessel of the calculated Provision shall be made for replacing water loss from the size is not available, the next available larger size should be system either:—...
- Page 10 TECHNICAL DATA - Page 10 FIG 7. FULLY PUMPED SEALED SYSTEM...
- Page 11 INSTALLATION INSTRUCTIONS - Page 11 It is the law that all gas appliances are installed and serviced CARTON 2:—Flue System Pack by competent persons as stated in Gas Safety (Installation and Use) Regulations 1984. For Health and Safety Horizontal Flue Packs Information see back page.
- Page 12 INSTALLATION INSTRUCTIONS - Page 12 FIG. 10a SIDE FLUE FIG. 10b REAR FLUE Measure from outside face of wall to the side of boiler Measure wall thickness (dimension ‘Y’). casing reference line (dimension ‘x’). Take air/flue duct assembly and measuring from the Take air/flue duct assembly and measuring from the flanged end, mark and cut the outer air duct and inner flanged end, mark and cut the outer duct and inner flue...
- Page 13 INSTALLATION INSTRUCTIONS - Page 13 FIG. 13 PREPARING THE BOILER The controls cover should have been removed when The boiler may now be lifted onto its mounting bracket or if unpacking the boiler, if not remove controls cover by opening desired the appliance liftweight can be further reduced by the door covering the securing screw on the underside of removing the fan/fluehood assembly also the burner/ gas...
- Page 14 INSTALLATION INSTRUCTIONS - Page 14 LIFTING THE BOILER Lift the boiler onto its mounting bracket. FIG. 14 FIG. 15 TRANSPORTATION FOOT Locate the studs on the air duct flange through the boiler Position boiler on its mounting bracket so that the sides of casing and secure using four wing nuts (accessory pack F).
- Page 15 INSTALLATION INSTRUCTIONS - Page 15 FIG. 18 FLUE ELBOW EXTENSION When side fluing, slide the elbow extension onto the elbow, push on fully and align the hole for securing screw with arrow on elbow. Engage the screw from accessory pack ‘C’ into the pre-.drilled hole in elbow extension and screw fully FIG.19 LOCATION OF PRESSURE SENSING TUBES home.
- Page 16 This may not be required if a Potterton Electronic Programmer is used as this incorporates a junction box.
- Page 17 INSTALLATION INSTRUCTIONS - Page 17 FIG. 23 ROUTING OF ELECTRICAL WIRING Following the pump manufacturer’s instructions connect the pump supply wires to terminals marked PUMP LN on the boiler terminal block. Route the cable through the plastic bush in the rear of the control box as illustrated in FiG. 23 and secure, using the cable clamp.
- Page 18 COMMISSIONING - Page 18 Open Vented Systems Refit the combustion chamber front panel. Remove the pump and flush out the system thoroughly with Fit the case door into position by lifting it onto the top hinge cold water. Refit the pump. Fill and vent the system. brackets and secure it with the lower two fixing screws.
- Page 19 COMMISSIONING - Page 19 FIG. 25 MAIN BURNER PRESSURE ADJUSTMENT Shut down the boiler remove the pressure gauge and refit Pump Over-Run Thermostat the screw in the test nipple ensuring that a tight seal is made. Will keep the pump running after the boiler has shut down, as long as the water temperature within the boiler is above Refit the controls cover.
- Page 20 COMMISSIONING - Page 20 FIG. 26 FUNCTIONAL FLOW DIAGRAM HONEYWELL FIG. 27 BOILER WIRING DIAGRAM...
- Page 21 Servicing is best arranged by a contract placed with Before the start of any servicing work, switch off at the Potterton Myson Limited and further details are available external electricity supply by disconnecting the supply plug from the local Potterton Regional Service Office.
- Page 22 SERVICING INSTRUCTIONS - Page 22 Remove screws securing the combustion chamber front Unscrew the two hexagonal head screws securing the pilot panel and remove panel. to the main burner and remove the pilot assembly. Disconnect the two flexible tubes from the flue elbow. Lightly brush the pilot to remove any deposits.
- Page 24 SERVICING INSTRUCTIONS - Page 23 Refit the burner and gas control valve assembly into the MAIN BURNER boiler, ensuring that the locating pin on the rear of burner Switch off the external electricity supply by disconnecting engages correctly into the rear support bracket. Make sure the plug at the socket or switching off the external isolating that the sealing gasket is in place and undamaged switch.
- Page 26 SERVICING INSTRUCTIONS - Page 24 Remove main burner as described in Preparing the Boiler Disconnect the three electrical leads, white wire from for Servicing’, operations G, H, I, J & K terminal No.1 or NC, orange from terminal No.2 or NO and brown from terminal No.
- Page 27 SERVICING INSTRUCTIONS - Page 25 PUMP OVER-RUN THERMOSTAT Replacement is the reverse of removal. Taking care that the clear circle in the sight glass lines up viewing Remove door by undoing the lower fixing screws and hole in combustion chamber door. NOTE new gaskets lifting door off the two upper hinge brackets.
- Page 28 SERVICING INSTRUCTIONS - Page 26 FIG. 30 FAULT FINDING CHART Publication No. 559472/01 92...
- Page 29 SERVICING INSTRUCTIONS - Page 27 SHORT PARTS LIST KEY No. P.I.L Part No. Pilot and Electrode Assembly including items 2-6 402967 Pilot Injector 402968 Compression Nut 625934 Olive 625936 Electrode 407721 Screw 612351 Electrode Lead 407692 Control Thermostat K36 L1014 907729 Gas Control Valve - Honeywell 402911...
- Page 30 HEALTH AND SAFETY INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER - Page 28 Under the Consumer Protection Act 1987 and section 6 of the Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. Small quantities of adhesives and sealants used in the product are cured and present no known hazards.
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