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Wall Mounted, Fanned, Room Sealed Combination Boiler
THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1994 (AS AMENDED).
'' 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 these instructions and the rules in force in the country of destination.
The polythene bags used for packaging are a potential hazard to babies and young children and MUST BE DISPOSED OF
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 100 & 100e
IMMEDIATELY.
IMPORTANT
PLEASE READ THIS BOOK
BEFORE INSTALLING,
OPERATING OR SERVICING
THIS APPLIANCE.
27/19093 - 03
Part No.
Puma 100 - G.C. No. 47 590 12
Puma 100e - G.C. No. 47 590 13
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Summary of Contents for Potterton Puma 100
- Page 1 27/19093 - 03 Part No. Puma 100 - G.C. No. 47 590 12 Puma 100e - G.C. No. 47 590 13 Installation & Service Instructions Puma 100 & 100e Wall Mounted, Fanned, Room Sealed Combination Boiler THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1994 (AS AMENDED).
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Page 2: Table Of Contents
Contents Technical Data............3 Remove the Flue Hood ........26 Introduction ..............4 Remove the Combust. Cham. Front Panel ..26 Optional Extras ............5 To Inspect and Clean the Boiler ......26 To Remove the Burner ........28 1. Installation Requirements ......... 8 Gas Pressure Adjustment .......28 General Information........... -
Page 3: Technical Data
Technical Data - Page 3 Heat Input: Max. 36.0kW (122,870Btu/h) Range Rate (C.H. Only) 20.2kW (69,050Btu/h) Min. 15.5kW (52,880Btu/h) Heat Output: Max. 29.0kW (98,980Btu/h) Range Rate (C.H. Only) 15.5kW (52,880Btu/h) Min. 11.5kW (39,235Btu/h) Gas Rate Full 3.43m³/hr 121ft³/hr Inlet Pressure 20mbar (18 - 25mbar) Burner Pressure... -
Page 4: Introduction
'On', the combination boiler fires only when hot water is regulations and water Bylaws Scheme - Approved Products. drawn off. The Potterton Puma range of boilers are fully automatic, wall With the central heating switch set to 'Timed' the boiler will mounted, fan assisted, room sealed combination boilers, operate the central heating for the time periods set on the designed to operate on Natural Gas only. - Page 5 Optional Extras - Page 5...
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Page 6: Optional Extras
Optional Extras - Page 6 Installation instructions included as necessary with each kit. - Page 7 Optional Extras - -Page 7 Installation instructions included as necessary with each kit.
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Page 8: Installation Requirements
Acquaint 6891. yourself with the British Standards concerning installation requirements. If you need advice on any points, Potterton's Pipework from the meter to the combination boiler must be Service Operations will be pleased to help (see back page). -
Page 9: Location Of Boiler
Installation Requirements - Page 9 Location Of Boiler If in doubt advice must be sought from the Local Gas 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 10: Flue Terminal And Ducting
Installation Requirements - Page 10 One metre flue extension kits are available to extend horizontal flues to a maximum length of 3078mm. 90° In-line elbow kits and 135° In-line Bend kits are also available for more flexible siting. Horizontal flues can be set at 45°... -
Page 11: Air Supply
Installation Requirements - Page 11 The central heating output from the boiler can easily be downrated if a lower temperature drop across the system is prefered. If the central heating system requires an increased pump head a second circulating pump should be installed. The pump must be sited on the return to the boiler and electrically connected using a proprietry relay i.e. -
Page 13: Mains Water Feed C.h
Installation Requirements - Page 12 External Controls To obtain economical use of the appliance it is advisable to fit external controls. The controls can take the form of:- a) Time clock (two internal options are available Part No. 31-19053 - Electro-mechanical) Part No. -
Page 14: Pump Performance Curve
Installation Requirements - Page 13 To assess water hardness, immerse a test strip for about the vertical scale in the centre of the chart. one second in a water sample (NOT IN RUNNING WATER) so as to moisten all the zones. The system must be designed so that its hydraulic resistance does not exceed the available head unless an Inspect the strip after 1-2 minutes, check the zones, if two or... -
Page 15: Electrical Supply
Installation Requirements - Page 14 1.10 Electrical Supply 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 16: Clearance Around The Appliance
Installation Requirements - Page 15 1.11 Clearances around the Appliance. Side Clearance: The position selected for the appliance must provide the following minimum clearance which is necessary for operation and servicing, 25mm each side (side clearances have been incorporated into template). Top Clearance: The top clearance should be a minimum of 160mm, but 300mm is preferred to allow removal of the central... -
Page 17: Boiler Installation
2. Boiler Installation - Page 16 It is MOST IMPORTANT that the appliance is installed in a c) Remove the base cover by removing the two fixing VERTICAL POSITION, with the flue system passing through screws and push the cover towards the rear to release the wall or ceiling in a Horizontal or Vertical plane. -
Page 18: D.h.w. Supply
Boiler Installation - Page 17 D.H.W. Supply If the shower control is existing and is of a mechanical type, it may be necessary to fit a drop tight pressure reducing a) The domestic hot water circuit does not need a pressure valve to the mains supply. -
Page 19: Pressure Relief Valve
Boiler Installation - Page 18 Pressure Relief Valve Wiring the Appliance The pressure relief valve is pre-set at 3 bar. The internal wiring of the appliance is shown in Figs. 42 & 46 . The wiring diagram is also on the inside of the front casing Install a pressure relief valve discharge pipe, not less than panel. -
Page 20: Commissioning
3. Commissioning - Page 19 The Puma combination boiler has been through a rigorous Gas Installation test procedure after manufacture and should not require any further adjustment. If in the unlikely event of the The whole of the gas installation including the meter, appliance not operating correctly please turn to the Control should be inspected and tested for soundness and purged Flow, Functional Flow and Fault Finding charts that start on... -
Page 21: Initial Lighting
Commissioning - Page 20 Initial Lighting Check that any time controls are in an On condition, and any room thermostats are calling for heat. (Fig. 20) Switch On the main electricity supply to the WARNING: Before operating the appliance, check that the combination boiler at the wall isolating switch. -
Page 22: Gas Pressure Adjustment
Commissioning - Page 21 o) Turn off the hot tap. Adjustment of the Modulating Valve Warning: Pressures are measured by connecting the +ve connection When the appliance is operating, wiring in the area to the gas outlet and -ve connection to the base of the inner around the gas valve and printed circuit boards will be casing as described in Section 3.3 (k). -
Page 23: Products Of Combustion Measurement
Commissioning - Page 22 Products Of Combustion Measurement The combustion performance can be assessed by placing a suitable sampling probe through the access hole in the inner casing door whilst the appliance is running. Typical figures based on a 500mm flue length with the boiler operating at maximum output are:- 0.002 - 0.005% 4.5 - 5.0%... -
Page 24: Flow Rate
Commissioning - Page 23 D.H.W Flow Rate condition the flow temperature can rise to 87°C at maximum setting. The appliance is fitted with a Central Heating switch which will allow you to switch Off the central heating during The appliance contains an automatic flow regulator the summer months (mid position). -
Page 25: Re-Fit Outer Case
Commissioning - Page 24 3.10 Refit the White Front Case. 3.11 Handing Over to the User After completion of installation and commissioning of the system, the installer should hand over to the Householder by the following actions: a) Explain to the Householder where to find the User's Guide and his/her responsibilities under the 'Gas Safety (Installation and Use) Regulations 1994. -
Page 26: Additional Information
Servicing - Page 25 It is preferable to measure the CO% and CO2% content of the flue products. This is achieved by placing a suitable sampling probe into the fluehood via the sample test point on the air box door. Typical figures based on a 500mm flue length with the boiler operating at maximum output are:- 0.002 - 0.005%... -
Page 27: Routine Maintenance
5. Routine Maintenance - Page 26 Routine Maintenance (Carry out the following sequence 5.1 - To Inspect and Clean the Boiler 5.10) (Fig. 24) Remove the White Front Case a. Inspect the heat exchanger for any blockage. Deposits (Fig. 15 in the Boiler Installation Section). of any material should be brushed away using a soft brush. - Page 28 Routine Maintenance - Page 27...
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Page 29: To Remove The Burner
Further (51 p.s.i) or higher if mains water pressure is higher. washers can be purchased from Potterton, Part No.13- 18693. If the boiler has been operating, care must be taken Note: If the portable pump can not easily be connected, the to avoid contact with any hot pipework on the underside of vessel can be removed and re-pressurised off the appliance. - Page 30 Routine Maintenance - Page 29...
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Page 31: Component Replacement
6. Component Replacement - Page 30 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 31 Central Heating Overheat Thermostat Sensor and Ignition Electrode Fig. 27 (Electronic versions only) a. Remove the white front case, base panel, air box covers a. Remove the white front case and three air box covers. and combustion chamber front panel. -
Page 33: Burner
Component Replacement - Page 32 Burner 6.10 Modulating Valve (Fig. 25) a. Remove the white front case. a. Remove the white front case, air box covers, See 5.1 in ’Routine Maintenance’. combustion chamber, front panel and burner assembly. b. Disconnect the electrical connections to the modulating See 5.1, 5.3, 5.6 &... - Page 34 Component Replacement - Page 33...
- Page 35 Component Replacement - Page 34...
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Page 36: Central Heating And Boiler Switch
Component Replacement - Page 35 6.14 Central Heating and Boiler Switches USER DISPLAY BOARD Remove the thermostat knobs and reset button. Undo the fixing screw retaining the facia panel and a. Remove the white front case and base panel. swing the panel downwards. See 5.1 &... -
Page 37: Air Pressure Switch
Component Replacement - Page 36 6.16 Air Pressure Switch 6.18 Fan Seals (Fig. 20 & 31) 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 right Maintenance’. hand side panel. -
Page 38: Water Flow Switch D.h.w
Component Replacement - Page 37 6.21 Water Flow Switch (D.H.W.) 6.23 Pump (Fig. 26) a. Remove the white front case and base panel. See 5.1 & 5.2 in ’Routine Maintenance’. For ease of replacement it is advisable to fit a new motor b. -
Page 39: Diverter Valve
Component Replacement - Page 38 6.24 Diverter Valve (Fig. 33) The diverter valve is made up in two parts. The wax capsule head forms one part and provides the motive power to open the valve. The second part, the valve consists of the change over mechanism and the valve seating. -
Page 40: Expansion Vessel D.h.w
Component Replacement - Page 39 6.25 Expansion Vessel D.H.W. Remove the top expansion vessel securing bracket assembly (four screws) and slide the vessel (complete (Fig. 34) with flexible pipe) upwards out of the appliance. g. Remove the flexible pipe from the old vessel and refit Isolate the electrical supply prior to this operation. -
Page 41: Heat Exchanger
Component Replacement - Page 40 6.26 Heat Exchanger (Fig. 24). Perform 5.1 to 5.6 & 5.8 in ‘Routine Maintenance’. Remove the combustion chamber insulation by removing each side panel retaining screw and pulling the complete side panel /insulation assembly forwards. The rear insulation can remain in situ. -
Page 42: Water Pressure Switch
Component Replacement - Page 41 Note: The outlet of the pressure relief valve is an olive connection. d. Fit the new pressure relief valve using a new ‘O’ ring seal and soap solution as a lubricant. Re-assemble in reverse order. e. -
Page 43: Schematic Diagrams - Permanent Pilot
7.1 Control Flow Sequence - Permanent Pilot - Page 42... - Page 44 7.2 Functional Flow - Permanent Pilot - Page 43...
- Page 45 7.3 Fault Finding - Permanent Pilot - Page 44...
- Page 46 7.4 Electrical Diagram - Permanent Pilot - Page 45...
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Page 47: Schematic Diagrams - Electronic
8.1 Control Flow Sequence - Electronic - Page 46... - Page 48 8.2 Functional Flow - Electronic - Page 47...
- Page 49 8.3 Fault Finding - Electronic - Page 48...
- Page 50 8.4 Electrical Diagram - Electronic - Page 49...
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Page 51: Short List Of Spares
9. Short List of Spares - Page 50... - Page 52 Short List of Spares Page 51 Item Description Potterton Gas Council Part No. Part No. Modulation Control Board - 100 929685 289 550 Modulation Control Board - 100e 929686 289 551 Display Board - 100 929687 289 552 Display Board - 100e...
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