Potterton Puma Flowsure+ Installation & Service Instructions Manual
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Potterton Puma Flowsure+ Installation & Service Instructions Manual

Potterton Puma Flowsure+ Installation & Service Instructions Manual

Wall mounted, fanned, room sealed, storage combination boiler
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THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1994.
'' 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.''
The polythene bags used for packaging are a potential hazard to babies and young children
LEAVE THESE INSTRUCTIONS WITH THE USER FOR USE ON FUTURE CALLS
For Use With Natural Gas
(G20) Only At 20mbar
For Use in GB & IE
Installation & Service Instructions
Puma Flowsure+
Wall Mounted, Fanned, Room Sealed,
Storage Combination Boiler
and MUST BE DISPOSED OF IMMEDIATELY.
Puma Flowsure+ - G.C. No. 47 590 18
IMPORTANT
PLEASE READ THIS BOOK
BEFORE INSTALLING,
OPERATING OR SERVICING
THIS APPLIANCE.
27/20334 - 01
Part No.

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  • Page 1 27/20334 - 01 Part No. Puma Flowsure+ - G.C. No. 47 590 18 Installation & Service Instructions Puma Flowsure+ Wall Mounted, Fanned, Room Sealed, Storage Combination Boiler THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1994. ‘‘ 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.

  • Page 2: Table Of Contents

    Contents - Page 2 Technical Data............3 Remove the Fan Assembly......27 Remove the Flue Hood......27 Introduction ............4 Remove the Combust. Cham. Front Panel ..........27 1. Installation Requirements........6 To Inspect and Clean the Boiler ....27 General Information........6 To Remove the Burner ......29 Location of Boiler...........7 Gas Pressure Adjustment......

  • Page 3: Technical Data

    Technical Data - Page 3 Boiler Details Connections - Water Heat Input: 30.00 - Max. Inlet DHW 15mm Compression Isolating Valve Btu/hr 102,350 Outlet DHW 15mm Copper Pipe 22.5 - Range Rate Flow CH 22mm Compression Isolating Valve Btu/hr 76,760 Return CH 22mm Compression Isolating Valve 14.4 - Min...

  • Page 4: Introduction

    Introduction - Page 4 GAS SAFETY (INSTALLATION AND USE) With the central heating switch set to 'Off' and the boiler REGULATIONS 1994. switch set to 'On', the combination boiler fires only when hot water is drawn off and occasionally to maintain the The appliance must be installed and serviced by a temperature of the stored hot water.
  • Page 5 Introduction - Page 5 Part No. 27/20334 Introduction 5...

  • Page 6: Installation Requirements

    First Aid - Medical attention must be sought following eye Any direct connection of a control device not recommended contact or prolonged reddening of the skin. by Potterton could invalidate the certificate and the normal appliance warranty and could also infringe the Gas Safety Heat Exchanger Regulations.

  • Page 7: Location Of Boiler

    Installation Requirements Page 7 Fig 2 If in doubt advice must be sought from the Local Gas Location Of Boiler Region of British Gas. In siting the combination boiler, the following limitations The combination boiler may be installed in any room or MUST be observed: internal space, although particular attention is drawn to the requirements of the current I.E.E.

  • Page 8: Flue Terminal And Ducting

    If the combination boiler is to be installed in a cupboard or compartment, permanent air vents are required The standard horizontal flue system (Potterton Part (for cooling purposes) in the cupboard/compartment, at both No.31-19619) is suitable for installations up to 1092mm, high and low levels.

  • Page 9: Guide To System Requirements

    Installation Requirements - Page 9 Ancillary pipework, not forming part of the useful heating surface, should be lagged to prevent heat loss and any Position of Air from Room/ Air Direct possible freezing, particularly where pipes run through roof Air Vent Internal Space from Outside spaces and ventilated under-floor spaces.

  • Page 10: Mains Water Feed C.h

    Installation Requirements - Page 10 Frost Protection necessary, an automatic pressure-reducing valve or flow restrictor. The tank of hot water will provide frost protection. This is The pressure booster pump must be capable of pressurising purely for the protection of the appliance. If any other part of the system to a minimum of 1.0 bar (14 p.s.i.) measured at the the central heating system requires frost protection, an appliance.

  • Page 11: Domestic Hot Water - 50 Litre Tank

    Installation Requirements - Page 11 HOW TO USE FIG. 6. adjuster, located on the electronic modulation control board (see Fig. 26). Starting with the required SYSTEM HEATING LOAD, draw a The boiler central heating output can be adjusted between the vertical line downwards so that it intersects the chosen maximum and minimum values stated on the data badge.
  • Page 12 Installation Requirements - Page 12 IMPORTANT No Valves should be fitted between the expansion vessel and the storage cylinder. DHW Store Temperature Water is stored in the tank at approximately 73°C. To ensure a safe delivery temperature a thermostatic mixing valve is fitted in the hot water outlet and should be adjusted to produce a hot water delivery temperature of 60°C.

  • Page 13: Electrical Supply

    Installation Requirements - Page 13 1.11 Electrical Supply (See Fig. 8 & 9) Wiring external to the appliance MUST be in accordance with the current I.E.E. Regulations for Electrical Installations, and any Local Regulations which apply. The combination boiler is supplied for 230 Volts ~ 50 Hz, Single Phase. To protect the appliance it is essential that the electrical supply is fused at 3 A rating.

  • Page 14: Clearance Around The Appliance

    Installation Requirements - Page 14 1.12 Clearances around the Appliance. (See Fig.11) Side Clearance: The position selected for the complete appliance must provide the following minimum clearance which is necessary for operation and servicing, 25mm each side of the unit (left hand side clearance has been incorporated into template).

  • Page 15: Installation

    2. Installation - Page 15 It is MOST IMPORTANT that the appliance is installed in a a) Remove the white front case as follows; undo the two VERTICAL POSITION, with the flue system passing securing screws at the base of the panel, pull the base through the wall or ceiling in a Horizontal or Vertical of the panel forward approx.
  • Page 16 Installation - Page 16 Mark out the position of the flue outlet and the three boiler mounting holes. Offer the mounting bracket assembly up to the template and mark two hole positions for the tank bracket. Remove the assembly and put to one side. At this point follow the Installation Instructions supplied with the Flue System for the installation of the flue only, then proceed as follows:-...

  • Page 17: Installation - Storage Tank

    Installation - Page 17 frame as shown. See Fig. 15. Connect the tundish assembly to the temperature & pressure valve as shown in Fig. 15. The tundish must be left visible to the consumer once installed and must not come into contact with any electrical components. Connect the pipe supplied to the temperature &...

  • Page 18: Supply

    Installation - Page 18 Showers: If a shower control is to be supplied from the Combination unit it should be of the type which incorporates a pressure balancing valve (e.g. MIRA 415 EQUAMATIC). If the shower control is existing and is of a mechanical type, it may be necessary to fit a drop tight pressure reducing valve to the mains supply.

  • Page 19: Wiring The Appliance

    Installation - Page 19 c) Connect the thermostat harness to terminals 1 and 3 of Wiring the Appliance the thermostat. Spread heat sink compound onto the thermostat sensing bulb and insert it into the bottom of The internal wiring of the appliance is shown in Figs. 36 & 37. the tank.

  • Page 20: Commissioning

    3. Commissioning - Page 20 The Puma Flowsure+ storage combination boiler has been Gas Installation through a rigorous test procedure after manufacture and should not require any further adjustment. If in the unlikely The whole of the gas installation including the meter, event of the appliance not operating correctly please turn to should be inspected and tested for soundness and purged the Control Flow, Functional Flow and Fault Finding charts...

  • Page 21: Initial Lighting

    Commissioning - Page 21 on the control panel are set to minimum. Initial Lighting (See Fig. 20) Check the Gas service cock is On. Check that the boiler isolating valves and radiator valves WARNING: Before operating the appliance, check that are open.

  • Page 22: Gas Pressure Adjustment

    Commissioning - Page 22 Note: It is important to note the order in which the maximum and minimum pressures are set. WARNING: When the appliance is operating, wiring in the area around The maximum pressure must always be set before adjustment the gas valve and printed circuit boards will be live.

  • Page 23: Products Of Combustion Measurement

    Commissioning - Page 23 Products Of Combustion Setting Measurement Tolerance Gas Rate Pressure The combustion performance can be assessed by placing Maximum 15.2 mbar 2.79 m a suitable sampling probe through the access hole in the 15.0 mbar Pressure 14.8 mbar 98.1 ft inner casing door whilst the appliance is running.

  • Page 24: Flow Rate

    Commissioning - Page 24 D.H.W Flow Rate Appliance Protection Devices The appliance contains an automatic flow regulator Loss of gas supply, flame failure, or over-heating of the supplying a nominal flow rate of 12 litres/minute. central heating water will cause the appliance to shut down or Lockout.

  • Page 25: Re-Fit Outer Case

    Commissioning - Page 25 3.10 Refit the White Front Case. a) Re-fit the right hand side boiler panel to the right hand side of the tank frame. b) Re-fit the left hand side boiler panel to the left hand side of the boiler.

  • Page 26: Servicing

    4. Servicing - Page 26 To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage but in general, once per year should be adequate.

  • Page 27: Routine Maintenance

    5. Routine Maintenance - Page 27 Routine Maintenance (Carry out the following sequence 5.1 - To Inspect and Clean the Boiler 5.10) (See Fig. 23) 5.1 Remove the White Front Case a. Inspect the heat exchanger for any blockage. Deposits (See Fig.
  • Page 28 Routine Maintenance - Page 28 28 Routine Maintenance Part No. 27/20334...

  • Page 29: To Remove The Burner

    Further washers can be purchased from Potterton, Part No.13-18693. If the boiler has been operating, care must be taken to avoid contact with any hot ceramic fibre board or pipework on the underside of the appliance, during inspection and cleaning.
  • Page 30 Routine Maintenance - Page 30 30 Routine Maintenance Part No. 27/20334...

  • Page 31: Component Replacement

    6. Component Replacement - Page 31 WARNING: Before attempting to remove any component from this appliance, first disconnect the mains electricity supply by removing the plug from the wall socket or by switching off the appliance at the external isolating switch. Note: The appliance stand-by switch must not be used as the means of isolating, as this switch does leave parts of the appliance electrically live.

  • Page 32: Central Heating Overheat Thermostat

    Component Replacement - Page 32 d. Fit new lead in correct position. Central Heating Overheat Thermostat e. Re-assemble in reverse order. Ensure the silicone See Fig. 26 grommet is correctly fitted and not damaged. Replace if necessary. Remove the white front case and three air box covers. See 5.1 &...

  • Page 33: Modulating Valve

    Component Replacement - Page 33 Modulating Valve 6.11 Central Heating and Boiler Switches a. Remove the white front case. a. Remove the white front case and base panel. See 5.1 in ’Routine Maintenance’. See 5.1 & 5.2 in ‘Routine Maintenance’. b.
  • Page 34 Component Replacement - Page 34 34 Component Replacement Part No. 27/20334...

  • Page 35: Electronic Control Boards

    Component Replacement - Page 35 Note: The board has a replaceable fuse rated at 2A. 6.12 Electronic Control Boards (see Fig. 28) a. Undo the fixing screw retaining the control box door. The electronic control assembly is in three parts: b.

  • Page 36: Air Pressure Switch

    Component Replacement - Page 36 6.13 Air Pressure Switch 6.15 Fan Seals (see Fig. 20 & 29) a. Remove the fan. See 5.1, 5.2, 5.3 & 5.4 in ‘Routine a. Remove the white front case, base panel and white Maintenance’. right hand side panel.

  • Page 37: Pump

    Component Replacement - Page 37 6.18 Pump 6.19 Expansion Vessel C.H. (See Fig. 25) Note: In the unlikely event of a failure of the C.H. For ease of replacement it is advisable to fit a new expansion vessel it is recommended that a new vessel motor (head) assembly to the existing pump housing.

  • Page 38: Heat Exchanger

    Component Replacement - Page 38 PROCEDURE 2 6.20 Heat Exchanger (See Fig. 23). If the clearance above the appliance is less than 300mm a. Perform 5.1 to 5.6 & 5.8 in ‘Routine Maintenance’. the appliance must be removed from the wall. Remove the combustion chamber insulation by removing each side panel retaining screw and pulling a.

  • Page 39: Automatic Air Vent

    Component Replacement - Page 39 6.21 Automatic Air Vent (See Fig. 30) a. Remove the white front case, base panel and white left hand side panel. See 5.1, 5.2 & 5.3 in 'Routine Maintenance'. b. Close the central heating isolating valves, reduce the system pressure by opening the pressure relief valve, then part drain the water from the boiler by opening the bleed valve on the right hand side of the diverter valve.

  • Page 40: Transformer Assembly

    Component Replacement - Page 40 6.23 Transformer Assembly (See Fig. 32) a. Remove the white front case and base panel. See 5.1 & 5.2 in ’Routine Maintenance’. b. Lower the control panel assembly by undoing the securing screw at the top right hand side of the control panel.

  • Page 41: Fault Finding

    7. Fault Finding - Page 41 Before attempting any electrical fault finding, carry out a preliminary electrical test by checking: for short circuits, fuse failure, incorrect polarity, earth continuity and resistance to earth. For replacement of fault component, (see Section - Component Replacement). To assist in fault-finding, the logic sequence of the electronics control circuit precedes the fault-finding charts.

  • Page 42: Control Flow Sequence

    8. Control Flow Sequence - Page 42 42 Control Flow Sequence Part No. 27/20334...

  • Page 43: Functional Flow

    9. Functional Flow - Page 43 Part No. 27/20334 Functional Flow 43...

  • Page 44: Schematic Wiring Diagram

    10. Pictorial Wiring Diagram - Page 44 44 Pictorial Wiring Diagram Part No. 27/20334...

  • Page 45: Electrical Diagrams

    11. Electrical Diagram - Page 45 Part No. 27/20334 Electrical Diagram 45...

  • Page 46: Short List Of Spares

    12. Short List of Spares - Page 46 Item Description Potterton Gas Council Part No. Part No. Modulation Control Board 21/20324 Display Board 21/20323 Full Sequence Control Board 21/18602 Pump Kit (Myson Compact) 10/18709 Main Burner Assembly 10/20162 Transformer 21/19646...
  • Page 47 Short List of Spares - Page 47 Back page Part No. 27/20334 Short List of Spares 47...

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