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Potterton Envoy Flowsure Installation & Service Instructions Manual

Wall mounted fan powered balanced flue gas condensing combination boiler and storage combination boiler
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Wall Mounted Fan Powered Balanced Flue Gas Condensing
Combination Boiler and 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. Failure to install appliances correctly could lead to prosecution.''
The polythene bags used for packaging are a potential hazard to babies and young children and
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
For Use With Natural Gas
(G20) Only At 20mbar
For Use in GB & IE
Installation & Service Instructions
Envoy Flowsure & Envoy Flowsure+
MUST BE DISPOSED OF IMMEDIATELY.
Boiler Module - G.C. No. 41 607 89
20 Litre Tank Module - G.C. No. 114 792
50 Litre Tank Module - G.C. No. 114 793
IMPORTANT
PLEASE READ THIS BOOK
BEFORE INSTALLING,
OPERATING OR SERVICING
THIS BOILER.
1

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  • Page 1 20 Litre Tank Module - G.C. No. 114 792 50 Litre Tank Module - G.C. No. 114 793 Installation & Service Instructions Envoy Flowsure & Envoy Flowsure+ Wall Mounted Fan Powered Balanced Flue Gas Condensing Combination Boiler and Storage Combination Boiler THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1994.

  • Page 2: Table Of Contents

    Boiler Internal Wiring..........35 Flame Sensor............. 25 Boiler Wiring Layout ..........36 Short List of Spares ..........37 Introduction - Page 2 The Potterton Envoy Flowsure (20 ) and Flowsure+ (50 ) are Accessories high efficiency, lightweight, automatically controlled wall...

  • Page 3: Technical Data

    Technical Data – Page 3 Boiler Details Boiler Details Cont... Flue Size 100mm Concentric Heat Input 26.86 Water Capacity 3.4 litre Btu/hr 91,600 ___________________________________________ Heat Output, NON-CONDENSING 23.45 Storage Tank Details - 20 Litre Btu/hr 80,000 Heat Output, Packed Weight 20kg CONDENSING 25.0...
  • Page 4 Technical Data – Page 4 Fig. 2 Technical Data Publication No. 559779...

  • Page 5: Installation Requirements

    (see back page). Insulation and Seals Samples of the Envoy Flowsure and Envoy Flowsure+ have been examined by Gastec, a Netherlands Notified Material - Ceramic Fibre. Alumino - Silicone Fibre. Body. The range is certified to comply with the essential Description - Boards, Ropes, Gaskets.
  • Page 6 Only the flue systems shown here can be fitted to the British Gas or from Potterton Myson. Envoy Flowsure and Flowsure+ boilers. If the terminal is fitted less than 2m (6.6 ft) above a...
  • Page 7 Installation Requirements – Page 7 A protective guard is available from the Potterton Myson through ventilators, windows, doors, natural air Sales Office whose address and telephone number are infiltration, or forced ventilation/air conditioning. If shown on the rear cover. The guard (Part No 236591)
  • Page 8 The Envoy Flowsure and Flowsure+ have an aluminium the drain off cap positioned within the boiler case. alloy heat exchanger, therefore all systems need to be...
  • Page 9 Installation Requirements – Page 9 with the relevant recommendations of BS 5546. Copper comprising a cistern, pressure booster pump and if tubing to BS 2871:1 is recommended for water carrying necessary, an automatic pressure-reducing valve or pipework and MUST be used for pipework carrying flow restrictor.
  • Page 10 Installation Requirements – Page 10 80,000 DIFF FLOW RATE CP63 10°c 0.56 14°c 0.40 16°c 0.35 18°c 0.31 20°c 0.28 To ensure sufficient pump head is available to overcome system resistance, a system differential of 14° should be allowed for. Litres / Sec EN0017A Domestic Hot Water - 20 Litre Tank...

  • Page 11: Installation Requirements

    Installation Requirements – Page 11 Air Vent Mixing Temperature / Temperature Mixed Domestic Valve Pressure relief valve Sensor Hot Water 6.5 1/ min Boiler Water Boiler Water Flow Return Flow Rate Domestic Cold Limiter Water Entry Temperature Sensor Mixed Domestic Hot W ater 12.0 l / min Mixing...

  • Page 12: Installation

    2. Installation – Page 12 It is the law that gas appliances are installed and serviced by a competent person as stated in the Gas Safety (Installation & Use) Regulations 1994. Electrical test work should be carried out by a competent person in accordance with IEE wiring regulations. The boiler and its associated equipment will arrive on site in 4 cartons.
  • Page 13 Installation – Page 13 Publication No. 55977 Installation...
  • Page 14 Installation – Page 14 Assemble the tank piping jig to the boiler mounting frame as illustrated. Using 10 off wall plugs and screws from accessory pack Tundish attach the boiler mounting frame and tank piping jig to the wall ensuring that they are level. T &...
  • Page 15 Installation – Page 15 Pressure Relief Valve: The Flowsure has one P.R.V. fitted within the boiler pre-set at 3 bar. The Flowsure+ has two P.R.V's fitted, one within the boiler pre-set at 3 bar and one within the tank controls pre-set at 6 bar. Install a pressure relief valve discharge pipe to the boiler and tank valves, not less than 15 mm diameter and connect to the pressure relief outlet connection using a 15mm...

  • Page 16: Commissioning

    3. Commissioning – Page 16 All Systems Ensure the electronic timer if fitted, is in an 'ON' period (refer to the time control literature). Note: The system can be filled using a sealed system filler pump with a break tank or by any other method Ensure that the room thermostat if fitted is set to a high approved by the Local Water Authority.
  • Page 17 Potterton Myson Service Department should be called as specialist equipment is required to enable adjustment to be made.
  • Page 18 Commissioning – Page 18 Final Assembly Information must also be passed to the customer on the type of corrosion inhibitor that has been added to the Remove the three M5 pozi head screws from the right hand system and of the need to maintain the correct side of the boiler as shown, Secure the centre case support concentration levels as recommended by the bracket using the three screws previously removed.

  • Page 19: Boiler Display & Controls

    4. Boiler Display & Controls – Page 19 Under normal conditions of operation the following characters appear:- Central Heating Display not illuminated. All power off. Switch Stand-by: This is displayed when the CH & DHW switches are in the 'Off' position. Also shown when both Domestic Hot Water switches are in the 'On' position but there is no call for Switch...
  • Page 20 Boiler Display & Controls – Page 20 Note: If you hold the Lockout Reset/Function Button for Storage Tank: The 50 litre is set at 50 and the 20 litre more than 5 seconds you will enter the installer tank is set at 20. The 20 litre may also use 00 in areas adjustment mode settings.
  • Page 21 Boiler Display & Controls – Page 21 Menu of Settings and Information available to the Installer Outdoor Weather Compensator - Optional Extra The information taken from the sensor is used in conjunction with some of the software settings within the controls and used to calculate the required boiler output/system temperature to match the heat load of the dwelling.

  • Page 22: Servicing & Replacement Of Parts

    5. Servicing & Replacement of Parts – Page 22 It is the law that all gas appliances are installed and serviced a) Set the boiler running to check its operation. by a competent person as stated in Gas Safety (Installation and Use) Regulations 1994.

  • Page 23: Removing Fan

    Servicing & Replacement of Parts – Page 23 Removing Fan 1) Disconnect electrical connection from fan motor. FIG. 15. 2) Disconnect flexible sensing tube from the fan inlet housing. 3) Remove fan by slackening two wing screws on left hand side and removing the M5 wing screw on the right hand side of the fan.

  • Page 24: Examination Of Flueways & Cleaning

    The insulation in the combustion chamber. Note if there 2) Cleaning of the heat exchanger must be carried out is any visible deterioration of this material it MUST be using a Potterton scraper Part No. 907736. replaced Damage to the hot surface igniter...

  • Page 25: Replacement Of Parts

    Servicing & Replacement of Parts – Page 25 Replacement of components is the reverse of removal. tightened and that the clamps fix the combustion chamber and flue hood securely. Note: great care should be taken not to damage the flue hood and combustion chamber seals during 10) Ensure connection from sump to syphon is made replacement of these assemblies.

  • Page 26: Burner

    Servicing & Replacement of Parts – Page 26 4) Insulation (Continued) 7) Flue Hood/Combustion Chamber Seals. Carefully replace burner. a) Remove combustion chamber/fluehood as described in 'Servicing Boiler' See Fig.16. g) Refit hot surface igniter and flame sensor. WARNING This component is fragile and requires b) Remove old seal.

  • Page 27: Sight Glass

    Servicing & Replacement of Parts – Page 27 10) Sight Glass (combustion chamber or case door). 12) Diverter Valve Head. Note: Care should be taken when handling and a) Remove decorative door and base panel as described disposing of broken glass. in 'Servicing Boiler'.

  • Page 28: Boiler Control Board

    Fig. 22. c) Remove screw retaining control front panel and tray. Fig. e) Remove old fuse and replace with the correct Potterton component T - 3.15A (Part No. 933005). d) Gently pull front panel forward removing connectors from the control as they become accessible.

  • Page 29: Water Components

    Servicing & Replacement of Parts – Page 29 Water Components. Replacement of Pump, Water Pressure Switch, Diverter Valve and Water Pressure Gauge. a) Remove decorative & functional doors as described in 'Servicing Boiler'. b) Remove blanking screw and attach a hose to the drain valve on the return pipe isolating valve.

  • Page 30: Fault Finding

    6. Fault Finding – Page 30 Error Codes Last Lockout: This is when a lockout has occurred and the control has been reset, this event is then stored in the controls memory until another lockout occurs and is reset at which time the display is updated to reflect the new event. The type of lockout is shown in the Flow Temperature &...
  • Page 31 Fault Finding – Page 31 Menu of Settings and Information Available to Installer Publication No. 55977 Fault Finding...
  • Page 32 Fault Finding – Page 32 Fault Finding Chart Publication No. 559779...
  • Page 33 Fault Finding – Page 33 Publication No. 55977 Fault Finding Chart...
  • Page 34 Fault Finding – Page 34 Fault Finding Chart Publication No. 559779...

  • Page 35: Boiler Internal Wiring

    7. Boiler Internal Wiring – Page 35 W ater Pressure Switch Case T emp Sensor Pump Gn/ Yl Gn/ Yl In - Line Connectors Diverter Valve Gn/ Yl Gn/ Yl Return Temp. Sensor Gas Valve Assembly Flow T emp. Sensor DHW ON / OFF Gn/ Yl Gas Valve Earth...

  • Page 36: Boiler Wiring Layout

    8. Boiler Wiring Layout – Page 36 Boiler Wiring Layout Publication No. 559779...

  • Page 37: Short List Of Spares

    9. Short List Of Spare Parts – Page 37 Drg. Description Potterton G.C. No. Ref. Part No. Gas Valve Assembly 402992 Injector 411010 409585 Control Assembly 407751 Temperature Sensor 404513 Burner 414732 Burner Gasket 236120 Fan Outlet Gasket 236253 Hot Surface Igniter...
  • Page 38 If the gas valve signal is outside the range check must be conducted on the whole appliance to ensure contact the Potterton Service Department. that any other faults present are found and rectified. 5. Enter the INSTALLER MODE on the control board and set the MINIMUM fan speed G to 99.
  • Page 39 0.1 to 0.5% from maximum to minimum modulation, re-adjust the gas valve if Lower Adjustment necessary. If after adjustment the CO2 concentrations Band are outside these limits contact the Potterton Service Boiler CO Maximum Modulation Department. Minimum Modulation Boiler CO2 - 8.3% ± 0.3% Gas Valve Signal mbar 8.

This manual is also suitable for:

Envoy flowsure+

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