may 2004 - the initiative · the potterton derwent compact plus condensing cast iron sectional...

MAY 2004

Index

Section 1 PageFig 1 General Data and Dimensions 1Table 1 Boiler Dimensions 1Table 2 Connections 1Table 3 Technical Data 2Fig 2 Steel Base Strip Details 3

Clearances 3

Section 2General 4Optional Extras 4Installation 4Boiler Siting and Base 5

Section 3Ventilation 6- flue 6- flue Size Considerations 6- horizontal Flue Runs 6- common Flue Systems 6Water Circulation Systems 6Boiler Protection 7System Water Quality 7- existing Systems 7- new Systems 7Sealed Systems 7- noise level 7

Section 4Boiler Installation 8- risk Assessment 8- manual Handling 8- personal Protective Equipment 8- confined Spaces 8- electrical Safety 8- preparation 8COSHH 8Customer Check List 9Unpacking Boiler 9Boiler Main Components 9Control and Safety Equipment 10Working Principles 10Hydraulic Test of Boiler 10- connecting the Water System 10- condensate 10- connecting the Electrical Supply 10- connecting the Flue 11- connecting the Gas Supply 11- boiler Controls 11

Section 5Potterton Commercial CustomerCommissioning Check List 12- contravention of regulations 12- commissioning 12

PageControl Panel 13Gas Assembly 14Set Up 14Adjusting the Air 14Low Load Control & Set Up 15Important Safety 15Emergency Instructions 15Addition Checks 16Pre-Lighting 16Commissioning Live Run 16Ionisation Current Check 17Ventilation Checks 17Operation of Ancillary Controls 17Boiler Maintenance 17Boiler Cleanin 18-19Water Flow Swtich 20Fault Finding 20-22- overheat operation 20- burner lockout 20- general arrangement of pilot burner 20

Section 6Wiring Diagram 23-24

Section 7Spare Parts Lists 25-34

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 1INSTALLATION, OPERATION AND MAINTENANCE MANUAL

DERWENT COMPACT PLUS – CONDENSING PAGE 1

Fig 1 – General Data and Dimensions

Table 1 – Boiler Dimensions

Size A B C D E ØF G H I Return Flow4 456 1200 1050 1150 1130 182 157 81 87 1 ¼” 1 ¼”6 537 1200 1050 1194 1140 202 197 45 51 1 ½” 1 ½”8 699 1390 1255 1194 1140 252 283 45 51 1 ½” 1 ½”

B

C

Flow

Return

1400

G

ØF263 I

874

H

868

D A

E

1300

14324

3

1004

Ø34

93160 485

Gas

Condensate

Note:Maximum Working Temp 90°CMaximum Working Pressure 3 BarElectrical Supply 230V 50Hz

Table 2 - Connections

4 6 8Water 1 ¼” 1 ½” 1 ½”Drain ½”Gas 1 ¼”

SECTION 1 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION AND MAINTENANCE MANUAL

PAGE 2 DERWENT COMPACT PLUS – CONDENSING

Table 3 – Technical Data

Model: Derwent Compact Plus Condensing 4/55 6/90 8/125Number of Sections 4 6 8CE Certification Number 0063B03166Gas Category I2HNominal Heat Input 100% kW 54 90 125Nominal Heat Input 80% kW 43.2 72 100Nominal Heat Output 100% load 60/80°C kW 51.4 85.9 118.6Nominal Heat Output 100% load 30/50°C kW 55.5 92.5 127.9Nominal Heat Output 80% load 60/80°C kW 41 69 95Nominal Heat Output 80% load 30/50°C kW 45.3 75.7 104.4Fuel Consumption 100% load (NG) m³/hr 5.7 9.5 13.2Fuel Consumption 80% load (NG) m³/hr 4.6 7.6 10.6Nominal Gas Inlet Pressure (NG) mbar 20Burner Manifold Pressure 100% (NG) mbar 16.5Burner Manifold Pressure 80% (NG) mbar 10.5Burner Injector Size (NG) mm 3.2Maximum Design Pressure bar 3Minimum Operating Pressure bar 0.5 (0.1 available on request)CO2 NG 100% load % 7.5 to 8.5 6.5 to 7.5 7.5 to 8.5CO2 NG 80% load % 6.5 to 7.5 6.5 to 7.5 6.5 to 7.5Nominal Flue Connection Size Ømm 180 200 250Flue Gas Volume m³/hr 95 175 235Flue Draught Requirements mm 0-5Flue Gas Temperature 60/80°C (100%) °C 63 73 80Flue Gas Temperature 30/50°C (100%) °C 45 57 65High Level Natural Ventilation to BS6644 cm² 270 337.5 416.25Low Level Natural Ventilation to BS6644 cm² 540 675 832.5Mechanical Inlet to BS6644 m³/sec 0.059 0.099 1.375Water Flow Rate at 11°C ∆T at 100% lit/sec 1.21 2.01 2.78Min Water Flow Rate at 20°C ∆T at 100% lit/sec 0.66 1.11 1.53Hydraulic Resistance at 11°C ∆T kpa 30.6 48.97 66.32Cold Feed Size to BS6644 or BS5440Minimum Bore

mm 19 25

Safety Valve Size to BSS6644 or BS5440Minimum Bore

mm 25 32

Safety Valve Size to BS6644 or BS5440Nominal Size

mm 19

Maximum Flow Temperature °C 90Minimum Return Temperature °C 30Air Pressure Switch 100% Pa 50-64 400-427 400-427Air Pressure Switch 80% Pa 20-34 150-174 150-174Dry Weight Kg 252 345 437Water Content Lit 28.3 39 54.3Power Requirements 230V 50Hz 1Ph – Isolator and 6.3A Fuse

Required


DERWENT COMPACT PLUS – CONDENSING PAGE 3

Fig- 2 – Steel Base Strip Details – (see section 2 – Boiler Siting and Base)

The boiler feet MUST NEVER be fixed in position (this is to allow for expansion).

Sections 4 6 8G mm 171 324 486

CLEARANCES

The minimum boiler room clearances for access, erection and maintenance are as follows: -

REAR - 500mm from rear of flue hood

SIDES - 10mm

FRONT - 700mm (to allow for burner removal)

TOP - 1000mm (to allow for cleaning)

Flammable products should never be stored in the space around the boiler. Any walls that are sensitive to heatshould be protected by an appropriate insulation.

G

485

710

Centre LineOf Boiler

75

FRONT OF BOILER

SECTION 2 POTTERTON COMMERCIAL PRODUCTS DIVISION

INSTALLATION, OPERATION AND MAINTENANCE MANUALPAGE 4 DERWENT COMPACT PLUS - CONDENSING

GENERAL

This boiler is NOT SUITABLE for installation in anormally occupied area (i.e. kitchen).

A LIFETIME GUARANTEE is available on this boiler,please refer to our standard terms and conditions fordetails.

The Potterton Derwent Compact Plus Condensingcast iron sectional boiler is available in three sizes.Table 3 (page 2) gives kW outputs and technical datafor each model. The boilers work on 2 stages, 100%and 80% of nominal output. They are approved to 3Star efficiency and have Class 5 NOx.

The Derwent Compact Plus Condensing is suitable foruse on fully pumped open vented systems or a sealedsystem with a maximum design pressure of 3 bar.

These boilers are delivered fully assembled on onepallet with burner, flue hood, gas train, control paneland case fitted.

For sites with restricted access the boiler block, withdrain off cock removed, will pass through a 660 mmdoorway.

If necessary the boiler block can be easily strippeddown into individual sections. (For section weights seepage 2) Our service office can offer this facility.

All boilers have the gas inlet on the left hand side.

The boiler sections are constructed with BS 1452grade 220 cast iron heat exchanger manufactured inaccordance with EN 303.1.

The boiler has a control system, which incorporatesfull safety features, which includes control and highlimit thermostats, thermometer and burner on/offswitch. All models have automatic ignition with asequential control box and an ionisation flame failuredevice fitted to an interrupted 400W pilot burner.

The boiler sections are insulated by 25mm glass fibreinsulation to front and rear and 50mm glass fibreinsulation on the sides and top. The case is finished ina powder coat paint.

RED – RAL 3001

GREY – (Non standard but closest match RAL 7024)

OPTIONAL EXTRAS

• Sequence control• Low Head Kit• Balancing Kit

It is recommended that the Potterton Commercial

Division’s trained engineers should carry outcommissioning, as this will make the LIFETIMEGUARANTEE valid.

INSTALLATION

The boiler should be installed in a clean boiler housefree of dust and corrosive vapours. During insulationof system pipework and heavy building constructionwork around the boiler, the boiler has to be switchedoff to avoid damage.

Before starting work a risk assessment should becarried out in the boiler house and its access toensure a safe installation and working environment.

Any person installing or working on the boiler must bequalified and attention is drawn to the mandatoryrequirements of CORGI. (ACOPS 16) registration forall Gas Installers. They must also be electricallycompetent and adhere to IEE regulations. Manual Handling:-. Any person or persons moving orlifting the boiler or any part thereof should be trainedin manual handling techniques and if necessary usesuitable lifting equipment to reduce the risk of injury tothemselves or other people.

The installation should comply with relevant BritishStandard Specifications, Codes of Practice andcurrent Building Regulations, together with any specialregional requirements of the Local Authorities, GasUndertaking and Insurance Company. All electricalwiring must comply with IEE. Regulations for theElectrical Equipment of Buildings.

The installation of the boiler must be in accordancewith the relevant requirements of:-

Health & Safety at Work Act 1974.

Building Regulations 1991

Electricity at work Regulations 1989

Management of H&S at Work Regulations 1992

Manual Handling Regulations 1992

Model Water By-Laws 1986

Gas Appliance Directive: 90/396/CEE

Boiler Efficiency Directive: 92/42

Boiler Pressure Directive: 97/23/CEE

Low Voltage Directive: EN 50165 Other Standards: EN297 – EN656 – EN437 – EN677

BS 7671: 1992 - Requirements for ElectricalInstallations, IEE Wiring Regulations 16th Edition.

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 2

INSTALLATION, OPERATION AND MAINTENANCE MANUALDERWENT COMPACT PLUS – CONDENSING PAGE 5

BS 5440: 1990: Part 1 – Specification for Installationof Flues

BS 5440: 2000: Part 2 – Specification for Installationof Ventilation for Gas Appliances

BS 6644: 1991 – Installation of Gas Fired Hot WaterBoilers for Inputs Between 60 kW and 2MW

BS 7074: 1989: Part 2 – Application Selection &Installation of Expansion Vessels & AncillaryEquipment for Sealed Water Systems

BS 6880: 1988 – Codes of Practice for LowTemperature Hot Water Systems

BS 779: 1989 – Cast Iron Boilers for Central Heating& Indirect Hot Water Supply (Rated Output 44 kW andAbove)

CP342:2 – Centralised Hot Water Supply

Gas Safety (Installation & Use) Regulations 1998

IM/11 Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters.

IGE/UP/1 – Soundness Testing & Purging Procedurefor Non-Domestic Installations

IGE/UP/2 – Gas Installation Pipework, Boosters &Compressors for Industrial & Commercial Premises.

Manufacturer's notes must not be taken in any way asoverriding statutory obligations.

BOILER SITING AND BASE

The boiler should be sited in accordance with BS6644: 1991 with respect to protecting the boiler fromdamage, air for combustion and ventilation, dischargeof products of combustion, clearances for service andaccess, temperatures, noise levels, the disposal ofboiler water and the effects of flooding of the boilerhouse or seepage from a roof top boiler house. Seepage 4 for required boiler clearances for service andaccess.

A level non-combustible floor capable of supportingthe weight of the boiler filled with water, see Table 3together with any additional weight bearing down onthe base from connections, etc, must be provided.

The Derwent Compact Plus Condensing is designedto be installed directly on the boiler house floorprovided it is adequate but we would recommend thata base of adequate height off the floor so as to beraised in case of flooding, but also low enough toallow ease of erection is used. This should typically bea 50mm concrete plinth with an area equal to that ofthe plan of the boiler.

Heating systems must be installed so that watercannot be returned from the heating system to thedrinking water system to which it is connected toprevent the drinking water being contaminated by theheating water or chemicals used in the heating water.

Consideration should be given to fitting steel stripsbeneath the boiler feet for boiler base protection, seeFig. 2 for base details.

When preparing a site reference should be made toLocal Authorities and Building Regulations 1991.

Before any work takes place a Risk Assessmentshould be carried out to determine what possible risksare associated with the work which is taking place.


PAGE 6 DERWENT COMPACT PLUS - CONDENSING

VENTILATION

Safe, efficient and trouble free operation ofconventionally flued boilers is vitally dependent onthe provision of an adequate supply of fresh air to theroom in which the appliance is installed. Accountmust also be taken of any other fuel burningappliance existing or to be fitted when designing theventilation and combustion air systems.

IMPORTANT: the use of an extractor fan in the sameroom as the boiler (or in an adjacent room incommunication) can in certain conditions adverselyeffect the safe operation of the boiler and thereforemust be avoided.

Further guidance on ventilation for gas appliances isprovided by BS 6644: 1991 and BS 5440 1989 Part2.

FLUE

To ensure safe and satisfactory operation thechimney system, which may be individual or commonin the case of modular boiler installations, shall becapable of the complete evacuation of combustionproducts at all times. The effective height of thechimney terminal(s) above the boiler(s) flue outlet(s)shall ensure sufficient buoyancy to overcome theresistance of the bends, tees and runs of the fluepipe involved and shall terminate in a down draughtfree zone. The number of bends used should be keptto a minimum and runs of flue pipe less than 45° tothe horizontal should be avoided in order to complywith the recommendations made in BS 6644: 1991and British Gas publication IM/11 "Flues forCommercial and Industrial Gas Fired Boilers and AirHeaters". The third edition of the 1956 Clean Air ActMemorandum and the Building Regulations shouldbe strictly observed and approval obtained whereapplicable, combustion chamber details are given inSection 1.

The flue system must be designed to workspecifically to remove the products of combustion.

IMPORTANT: 90° square bends must not be used onthe flue system, including the boiler flue spigot, astraight length followed by an "easy sweep" or lobsterback bend should be used.

FLUE SIZE CONSIDERATIONS

Nominal flue connection sizes are given in technicaldata Table 3, these sizes refer to the boiler flueconnection spigot.

The actual size of the flue system will depend onindividual site applications. Below are generalconsiderations on sizing flue systems. These notes

are for guidance only and Potterton CommercialDivision cannot accept responsibility for any fluesystem designs.

Horizontal Flue Runs

Horizontal flue runs are not recommendedparticularly over 3m in length, where these areunavoidable, advice should be sought from a fluesystem specialist.

Common Flue Systems

Where multiple boilers are installed on a commonflue system then the flue system should be designedto ensure the correct operation of the flue on varyingload conditions. In particular that the appliance fluedraught is within the operating parameter under fullload and partial load conditions. For safe and reliableoperation of the boiler plant it is recommended thatthe variance in flue draught available at eachappliance under full and part load operation isdesigned to a minimum.

(It is essential that the services of a specialist fluesystem manufacturer are sought for the design ofcommon flue systems).

For further information regarding ventilation andflueing see Potterton Technical Bulletin No.4, currentissue or see relevant British Standard publicationBS6644: 1991.

THE ABOVE RECOMMENDATIONS ARE FORGENERAL GUIDANCE ONLY. POTTERTONCOMMERCIAL DIVISION CANNOT ACCEPTRESPONSIBILITY FOR FLUE SYSTEM DESIGNSBASED ON THE ABOVE RECOMMENDATIONS.

WATER CIRCULATION SYSTEMS

The water circulation system should be indirect andinstalled in accordance with the relevant parts ofBritish Standards Codes of Practice CP342.2 and BS6644: 1991.

The maximum and minimum design temperaturedifferential across the boiler should be 20°C and10°C and the boiler should be prevented fromoperating with flow rates giving a temperaturedifference across the boiler greater than 20°C basedon the full boiler output. Boilers operating underconstant flow conditions can be more accuratelycontrolled and are not subject to excessivetemperature stresses.


DERWENT COMPACT PLUS - CONDENSING PAGE 7

The boilers MUST NOT be fired under anycircumstances with less than the minimum waterflow.

On systems with variable flow rates due to flowreducing devices, ie. TRVs, zone valves, etc, orwhere the minimum heat demand, ie. summerdomestic hot water load, does not achieve theminimum boiler flow rate then consideration shall begiven to incorporating a primary loop system. Forfurther information see Potterton PublicationTechnical Bulletin No.1 Issue 2.

It is recommended that the system is designed togive a constant flow rate. For further information onwater circulation systems see Potterton publicationTechnical Bulletin No.1 and Technical Bulletin No.3current issue.

BOILER PROTECTION

The provision of pump overrun by a time delay relayor a thermostat situated in the flow pipe close to theboiler is essential to remove residual heat from theboiler.

The boiler and system should be protected bysuitable frost thermostats.

Never fill a hot boiler with cold water. Suddencooling may cause the cast iron to fracture underthe stress.

Unions and isolating valves should be fitted to theflow and return manifolds so that the boiler can beisolated from the system if the need arises.

SYSTEM WATER QUALITY

Boiler systems require the system water to becontrolled by the use of inhibitors to maintain aneutral pH and inhibit corrosion. The system pHshould be controlled between 7 and 8. On systemswith Aluminium components a pH above 8.4 cancause failure of the Aluminium. The water systemmust be free of leaks to prevent raw water make up,which will dilute any inhibitors, promote corrosion andform lime scale.

The system water should be checked as part of amaintenance programme as a minimum on an annualbasis to ensure that corrosion inhibitors and pH areadequate for continued protection.

Existing SystemsOn existing systems where boilers are being replaceddue to failure then the cause should be investigatedbefore installing new boilers. This can normally be

achieved by cutting open a failed boiler section andexamination for system debris or contamination. Lime scale is a positive indicator of continuoussystem water make up due to water loss. Evidence ofmagnetite (black sludge) in the system and theformation of gas in radiators causing air locking is apositive indicator of corrosion.Where an old system shows evidence ofcontamination then system cleaning should becarried out before installation of new boilers. Theheating system should be chemically flushed toremove any lime scale or corrosion and a corrosionand lime scale inhibitor added. Lime scale descalersif incorrectly used could cause any remaining systemdebris to continue to breakdown and contaminate thenew boiler causing boiler failure. Advice on system cleaning and suitable productsshould be sought from specialist suppliers of systemcleaners such as Fernox or Sentinel. It is important to note that corrosion inhibitor can onlybe used in an attempt to prevent corrosion fromoccurring, where a system has an existing corrosionproblem, inhibitors will be ineffective and the systemrequires cleaning.

On existing systems where comprehensive descalingand desludging cannot be carried out thenconsideration should be given to separating the newboiler system from the existing system pipe work bythe use of plate heat exchangers. New SystemsNew pipe work systems should be thoroughly flushedwith a suitable cleaning agent to remove debris andflux residues before filling. The system water shouldbe dosed with a suitable corrosion and lime scaleinhibitor. SEALED SYSTEMS

General

Potterton Commercial boilers are suitable for use onsealed systems designed in accordance with BS6644: 1991 and BS 6880 Part 2. In addition,reference should be made to the Health & SafetyExecutive guidance note PM5 "AutomaticallyControlled Steam & Hot Water Boilers".

Noise Level

Derwent Compact Plus Condensing boilers areregarded as being ‘commercially quiet’, ie < NR63under typical operating conditions.



BOILER INSTALLATION

A Lifetime Guarantee is available on this boiler whenthe Potterton Commercial Service Department carriesout Commissioning and the system meets with ourrecommendations. Please refer to our StandardTerms and Conditions for further details.

Risk Assessment

Before starting work a risk assessment should becarried out in the boiler house and its access todetermine and ensure a safe installation and workingenvironment.

Regardless of the type of activity being assessed, theprinciples of risk assessments are the same. Thebasic steps are: -

• Classify Activity• Identify Hazards• Identify Existing Control Measures• Determine Risk• Assess Acceptability of Risk• Prepare a Control Plan• Implement Plan• Review Plan• Record Results

Manual Handling

Any person or persons moving or lifting the boiler orany part of the boiler, should be trained in ManualHandling Techniques and if necessary use suitablelifting equipment to reduce the risk of injury tothemselves and other people.

Personal Protective Equipment

When undertaken any work you must comply with thePersonal Protective Equipment Regulations 1992.

Confined Spaces

A “confined space” as defined in the Health andSafety Confined Spaces Regulations 1997 ‘ meansany place, including any chamber, tank, vat, silo, pit,trench, pipe, sewer, flue, well or other similar space inwhich, by virtue of its enclosed nature, there arises areasonably foreseeable specified risk.

Precautions should be taken in all areas where, byvirtue of its even partially enclosed nature, pose areasonably foreseeable specified risk.

Electrical Safety

Working on appliances can be broken down to twomain systems of work.

1 Safe systems of work are adapted for all boilermaintenance & repair work undertaken on site.

2 The work undertaken does not affect the electricalsafety of the appliance. In particular the earthconnected to the buildings fixed electricalinstallation.

In the case of (1) above electrical work should only beundertaken once the boiler has been isolated from theelectricity supply and confirmed electrically dead. Ifthis is impractical then suitable precautions must beundertaken to prevent injury.

In the case of (2) above checks are specified toidentify any abnormality in the electricity supply to theboiler as well as to confirm that the boiler electricalconnections are reinstated correctly where it isnecessary to disconnect or reconnect any internalwiring within the boiler.

If it is necessary to disconnect and reconnect theappliance from the site electrical installation other thanmeans of a plug and socket then additional checksshall be undertaken by an approved engineer to checkthe earth loop impedance in accordance with IEEregulations.

Always carry out preliminary electrical safety checks.

All appliances and central heating systems must beprovided with their own means of isolation for safetypurposes especially during installation andmaintenance.

Preparation

Preparatory to installation of the boiler a check mustbe made to ensure that suitable facilities are availablefor off-loading the boiler and moving it into it finalposition ensuring all Manual Handling Techniques arefollowed. Particular attention must be paid to ensuringcleanliness of the boiler room.

COSHH

During the erection procedure there are a number ofitems which are subject to the Control Of SubstancesHazardous to Health (COSHH) Regulations, and mayrequire specialist Personal Protective Equipment(PPE) beyond what is normally required. Listed beloware the items subject to the COSHH Regulations andthe recommended precautions that should be taken.

For a full breakdown of any substances listed below,please contact the Commercial Technical Department.

1 Refractory Ceramic Fibre Insulation – Wear gloves, overalls and safety glasses. In thecase of an irritation rinse the affected area with



water and wash gently, in the case of eye contact,flush abundantly with water, if irritation persistsseek medical advice.

2 High Temperature Glass Fibre Insulation –Wear gloves, overalls and safety glasses. In thecase of an irritation rinse the affected area withwater and wash gently, in the case of eye contact,flush abundantly with water, if irritation persistsseek medical advice.

3 Adhesive – Wear gloves, overalls. In the case ofan irritation rinse the affected area with water andwash gently, in the case of eye contact, flushabundantly with water, and if irritation persistsseek medical advice. Inhalation – continuedexposure should be prevented.

4 Sealing Rope - Wear gloves, overalls. In the caseof an irritation rinse the affected area with waterand wash gently, in the case of eye contact, flushabundantly with water, and if irritation persistsseek medical advice.

Potterton Commercial Customer Check List

The items listed below have been put together as aguide to actions that should be completed before theerection/assembly of a boiler takes place.

1 Site access available for persons carrying out theproposed work.

2 Site Managers/Personnel aware that work will betaking place.

3 Risk Assessments carried out on possible riskswhich may effect the persons carrying out theproposed work.

4 When boilers are to be stripped and rebuilt, labourand transport should be provided for moving thesections from the delivery point to the finalerection point. If this is unable to be providednotice prior to attending site should be given.

5 Sections/casing etc, should be kept in a clean anddry area prior to erection/assembly.

6 Water should be available.

7 A drain off area should be available.

8 Power should be available.

9 A site representative should be available at alltimes.

10 Clear instructions supplied to the persons carryingout the proposed work regarding positioning theboiler.

11 Fire evacuation procedures, facilities availability,specific Health & Safety information, etc, shouldbe provided.

Items 7 to 10 are essential if boilers require pressuretesting.

UNPACKING BOILER

For all boiler sizes remove the wooden box, shrinkwrap polythene and the cardboard protecting theboiler. The boiler block is held to the pallet by fixingbrackets on the iron feet.

Before removing the boiler from the pallet a riskassessment should be carried out to ensure saferemoval. This should take into account that anyperson or persons moving or lifting boilers or anypart there of should be trained in manual handlingtechniques and if necessary use suitable liftingequipment to reduce the risk of injury tothemselves or other people.

When moving the boiler block into position theburner assembly should be removed if there isany likelihood of damage occurring.

Jacks and crowbars should not be used againstthe flow and return manifolds.

Boiler Main Components

The boiler is composed of the following maincomponents:

1. Gas Valve assembly including intermittent pilot.2. Low NOx burner bars.3. Primary Heat Exchanger (Cast Iron).4. Pipework assembly connection between primary

and secondary heat exchangers.5. Secondary Heat Exchanger (Stainless Steel).6. Damper for air flow control.7. Fan.8. Air pressure switches.9. Hydraulic assembly for water flow distribution in

the secondary heat exchanger.10. Control & Safety Equipment.11. Set-up components.



Control & Safety Equipment 1. Low Gas Pressure Switch2. Control Box Dungs3. Air Pressure Switches4. Overheat Thermostat5. Secondary Heat Exchanger Overheat Thermostat6. Combustion Chamber Overheat Thermostat

Set-up components

1. Damper for air flow control at 100% load2. Rheostat for air flow control at 80% load3. Control Board

Working Principles of the Derwent Compact PlusCondensing

The boiler has been designed to work as a two stageHigh/Low boiler. Full load (100%) for second stageand low fire (80%) for first stage. The firing of the

boiler works to the following operation:

1. Pre-purge takes place for a duration of 40seconds during which the pressure switches aretested. If the pressure switch for the second stageis not satisfied, but the first stage is satisfied, thecycle will go to the next step.

2. Pilot lights during the next 10 second period.

3. Main burner establishes and cross lighting takesplace. The boiler will remain for 60 seconds onfirst stage operation, even if the second stagethermostat is calling for heat. The main valvecontains a regulator which is in charge of firststage operation.

4. The boiler moves from the first stage operation tothe second stage operation (Nominal load) andremaining on this setting until the thermostat issatisfied. The main valve with its regulator ensurethe second stage operates correctly.

HYDRAULIC TEST OF BOILER

This is to be carried out on boilers assembled on siteor where water manifolds have been disturbed.

Fit a hydraulic test pump to the return manifold and fita valve to vent air from the flow connection.

Fill the boiler with cold water and, in accordance withBS 779: 1976, pressurise up to 1.5 times the designpressure, ie. 4.5 bar maximum, and observe for 30minutes.

Connecting the Water System

The flow and return connections should be made tothe appropriate manifolds following therecommendations of CP342 and PM5.It is essential that all pipework connections to theboiler are self-supporting, correctly aligned and allowfor free expansion of both boiler and pipework.Care should be taken in the pipework design toprevent strain on the connections. Excessive straincan leak to premature failure of the boiler, which isobviously outside the terms of our warranty.The use of expansion bellows to take up both axialand lateral movement is recommended.The flow and return connections are made at the rearof the boiler.

Condensate

The condensate siphon of the secondary heatexchanger is at the rear of the boiler. It is onlypermissible to drain the condensate directly into adomestic sewer system when the system consists ofcorrosion-resistant materials (e.g. PP pipe, stoneware



etc.). It must be possible for the condensate to drainfreely into a funnel. A trap must be installed betweenthe funnel and sewer system.

Connecting the Electrical Supply

The electrical supply should be 230V 1Ph 50Hz. A6.3A fuse and a suitable two pole isolator having acontact separation of at least 3mm in all poles has to be provided by the installer for isolation of the boiler.All on site wiring shall conform to IEE Regulations.

The live and neutral connections should be made tothe control panel terminal block. The earth connectionshould be made 50mm longer. The length of theconductors between the cord anchorage and theterminals must be such that the current carryingconductors become taut before the earth conductor ifthe cable or cord slips out of the cord anchorage. Thewiring diagrams are included in this manual and alsoon the door panel of the boiler.

For multiple boiler installations each boiler shall havean isolator and fuse as detailed above to protect theboiler and allow for maintenance.

Connecting the Flue

The fluehood has a vertical female outlet into whichthe flue should be fitted and sealed fitted (dimensionsgiven in General Data). It is recommended that asingle skin stainless steel fully sealed flue system beinstalled and the flue is suitable for condensingboilers.

Connecting the Gas Supply

The connection should be made to the maleconnection (size given in Table 2). A union andisolating valve should be fitted close to the boiler toallow disconnection of the boiler controls formaintenance and repair.

The gas supply should be made through a suitablemeter and the local gas undertaking should beconsulted to determine the suitability of the meter andgas supply to meet existing and additional demandsfor gas.

The installation should be made in accordance withthe requirements of the Gas Safety (Installation &Use) Regulations and all other regulations and Codesof Practice

In particular, before connecting the boiler, ensure thatthe gas supply has been purged of air and a manualvalve for isolation of the boiler is fitted in an accessibleposition, readily identifiable, adjacent to the boiler.

The gas supply should be supported adequately.

For large single and multiple boiler installationsconsideration should be given to the installation ofadditional gas meters to assist in the monitoring ofboiler performance.

Attention is drawn to the need for adequately sizedpipework according to the maximum gas demand formultiple boiler installations and each boiler shall beprovided with an isolating valve so that it is possible toisolate the boiler from a common gas supply formaintenance purposes. The gas train is fitted with alow-pressure switch, which is set to operate at aminimum gas pressure of 13mbar.

Boiler Controls

The operation of the boiler is under the control of it'sown control box, boiler thermostats, 2 air pressureswitches, gas pressure switch and overheatthermostats.

In addition, the boiler should be controlled by a timeswitch, frost thermostat, pump overrun facility and, formultiple boiler installations, a boiler sequencecontroller. The boiler can be controlled externally byremoving link D to G and providing a switch acrossthese terminals to control the boiler.

The high limit thermostat and burner lock out signalscan be picked up from terminals marked remoteindication. These are volt free contacts.

See boiler wiring diagram.



Potterton Commercial Customer CommissioningCheck List

The items listed below have been put together as aguide to what actions should be completed before thecommissioning of a boiler takes place.

1 Site access available for persons carrying outthe proposed work.

2 Site Managers/Personnel aware that work willbe taking place.

3 Boilers correctly erected and cased.

4 Risk Assessments carried out on possible riskswhich may effect the persons carrying out theproposed work.

5 Site wiring complete to boilers.

6 Boilers filled & vented.

7 Controls connected, operable and calling forheat.

8 Sufficient system heating load available to runthe boilers in order to complete combustionchecks.

9 All system pumps operational and available.

10 Gas supply completed, purged and ready foruse.

11 Flue system complete, adequate and fullyfunctional.

12 Permanent ventilation complete and adequate.

13 All safety systems fitted and fully operational(e.g. safety valves, fuel shut off devices, fluefans interlocked, etc.).

14 Safe working environment provided.

Contravention of Regulations

PLEASE NOTE THAT SHOULD ANY ITEMS BEINSTALLED ON A TEMPORARY BASIS, E.G.VENTILATION, FLUES ETC, THEN THECOMMISSIONING ENGINEER WILL NOT BE ABLETO COMMISSION THE BOILER

Commissioning

IMPORTANT: The boiler must be commissionedfollowing completion of installation. Operation ofan uncommissioned appliance may cause injury

to personnel and damage to the boiler/burner unit

and could invalidate the manufacturer'swarranties.

Commissioning should only be carried out bypersonnel approved and competent to do so. Thisfacility is available from Potterton Commercial ServiceOffices at the addresses as listed on the back page ofthis manual.

Before commencing to commission check thefollowing.1 Electrical supply is of correct voltage and

polarity and earthing is available withcertification that all electrical checks have beencarried out.

2 Gas supply is tested for soundness and purgedof air. Ensure that the burner is suitable forconnected gas supply and pressure.

3 Test for gas soundness of gas trains.

4 Appliance gas cocks are all turned off.

5 Gas supply is turned on at the meter.

6 Boiler and system are filled with water andoperating pressure is within appliance range.

7 Flow and return valves are open.

8 Any external controls and the on/off switch arein the “ON” position.

9 The circulating pumps are operational. Checkthat the pump is scheduled to run and not onpump overrun if the boiler has previously beenfired. Check that any flow proving interlocks arefunctional.

10 Check that the high limit thermostat has nottripped by pressing the green reset buttonunderneath the hexagon cap nut on the fascia.

11 Ventilation is adequate and, in the case ofmechanical ventilation systems, operation ofthe boiler is inhibited unless the ventilation fanis proved.

12 On mechanically assisted flue systems theoperation of the boiler plant should be inhibitedunless the mechanical flue system isoperational and flow proved.

13 The safety valve should be checked to ensurethat it is the correct size and pressure.


INSTALLATION, OPERATION AND MAINTENANCE MANUALDERWENT COMPACT PLUS - CONDENSING PAGE 13

14 The cold feed and open vent sizes should bechecked

Following completion of the above checks the burnershould be commissioned. Typical combustion figuresare detailed below. The combustion figures, etc.should be completed on the commissioning formprovided at the back of this manual and returned toPotterton Commercial at the address on the backpage.

Commissioning figures should be taken with the boilerat high fire and a flow temperature of 80°C. Thecombustion measurements should be taken in thesecondary flue at a minimum of 600mm above thedraught diverted.

GAS CO2 - See Table 3CO - 0 - 50 ppmFlue Gas Temp - See Table 3

Check and ensure that the boiler cableconnection internally of the boiler are connectedin accordan e to the drawing below.

Ignitionconnec

Btc

Main valve 2 staconnector 9 way

1 Ov2 Th3 Co4 Tu5 Co

s c

Ignition transformer - gaspressure switch,connector 6 way

Thermostatscables

Complementary gasvalve connector

Thermostatpocket

ge,

Ionisation
connector
tor
urner security
her ostat
on ctor
erhermntrbentr

mne

eat Thermostatometer

ol Thermostat Ø 6 mm?ol Sensor



Control Panel

The CE 100 module provides the followingfunctions:

- Operation at 1st Stage- Detection of boiler overheat, ionisation

probe fault- Ability to restrict max boiler temperature

using jumper at back of module- Indication of the operation mode of the boiler- Operation of 2nd Stage operation.

The CB 120 module provides the followingfunctions:

1. Reset Button2. Overheat Thermostat3. Overheat Indicator4. Lockout Indicator5. Mains Supply Indicator

6. On/Off Switch7. Override button for Safety Checks8. Override Thermostat (Set fully to the

right((maximum position)) allowing control bythe 1st Stage and 2nd Stage thermostats)

9. 6.3 Amp Fuse10. Boiler Thermometer

Gas Assembly

(8 Section Model Shown)

The Gas Assembly is pre-sefor use at high and low condThe 4 Section model has on8 section have one main gasvalve.The main gas valve has a twhigh and low load (left valve)The slave gas valve has sionly and its governor is pre-sThe governor has a yellow cup is shown below.

Set-up

For fine adjustment of commissioning in order to

Pump Switch (Not Used)

Pump IndicatorLight

Boiler TemperatureControl Thermostat

Green Indicator LightShowing 1st Stage Run(If light flashes indication ofoverheat fault)

2nd Stage Thermostat

2nd StageIndicator Light

CE 100

CB 1201

2

3

4

8

765

10

9
t at the factory readyitions.e main valve, the 6 & valve and one slave
o-stage governor for.ngle stage operationet at the factory.over and the setting

the gas valve on obtain the correct



burner manifold pressure the following procedureshould be followed:- Loosen the screw on the burner manifold

and connect a manometer and check thepressure available to the data in thetechnical data table.

- Take off the yellow governor cover.- Set up the valve to achieve the figures for

high and low load.

(Adjusting Full Load)

(Adjusting Low Load)

Adjusting the Air

Airflow flow control (CO2 Control at high load)The CO2 setting for full load is pre-set at thefactory. The installer has to verify the CO2content by taking a reading in the flue between200mm and 300mm from the top of the flueconnection. The Technical Data Table indicatethe range acceptable. The air can be re-set bythe damper on the inlet to the fan and altering thesecuring positioning on this damper.Arrangement shown on the next page.

Air flow rate control at high load by devicedirectly on the damper. The hole position defines

A - Adjusting screw for full loadB - Adjusting screw for low loadC - Cover

AB

C



the right damper positioning.

Model 4 6 8Hole Position 3 3 6

Low Load Control & Set-up:

The control and setting is carried out as high firesetting. The low fire set-up is achieved by theadjustment of the rheostat which is located at theinner side of the front panel. Rotating therheostat allows the correct resistance to beobtained as shown on the table below.Measuring the resistance is carried out by anohm meter connected as shown below:

Model 4 6 8ResistanceOhm

560 270 100

The resistance tolerance is about 5 Ohms

IMPORTANT: The boiler/burner units aremanufactured in accordance with ISO 9002. Acondition of the supply of the appliance forcompliance with this Quality Assurance plan isthe return of the appliance commissioning report.

Important – Safety

In the U.K. it is a legal requirement that when workingon gas appliances the engineer must be CORGIregistered. The manufacturer cannot be heldresponsible for any consequential damage, loss orpersonal injury as a result of customers failing tofollow these instructions, or as a result of misuse.

Emergency Instructions

The burners are designed and constructed to meet allof the essential requirements of the GAS APPLIANCEDIRECTIVE 90/396/EEC and under normalcircumstances should not give occasion to anyhazardous conditions. If such a condition should occurduring commissioning or subsequent use of this

product, be it a fault of the boiler or of any instrument,machine or service in the proximity of the burner thenthe GAS and ELECTRICITY supply to the burnershould be IMMEDIATELY ISOLATED until such timethat the fault has been investigated and rectified.

IMPORTANT After each adjustment, gas flow rateand flue gas analysis should be re-checked.

ALWAYS Use approved test equipment (continuallymonitoring electronic equipment is recommended).

NEVER Rely on a visual inspection of the flame as aguide to combustion quality.

Following/during commissioning of the burner unit thefollowing additional checks should be carried out.

1 Operation of the control, high/low and limitthermostats should be checked for correct

2 The flue draught available at the appliance flueoutlet should be checked under all operatingconditions (hot and cold) and should be within theboiler operating parameters, see Table 3.

3 The fuel supply to the appliance should beisolated and the burner operated to ensure safetyshut down and lockout of the burner on flamefailure.

4 Shut down of the boiler plant by external controlsdoes not cause a hazardous condition and pumpoverrun is provided to remove residual heat fromthe boiler.

5 Following commissioning the boiler overheat andcontrol thermostats should be set to the requiredoperating setting.

6 Following completion of commissioning thesoundness of all automatic fuel valves should bechecked for leakage.

Additional Checks

Where possible, the system should be checked toensure that following purging of air there is no rawwater make-up. In particular, when the system isoperated in the hot condition, there should be nodischarge of water from the safety valve, open vent orcold feed tank overflow that would otherwise lead tounregulated raw water make-up when the systemcools down.

Pre-Lighting

Before attempting to light the boiler start thecirculating pump and check that it is scheduled to run

Hole No 1



and not on pump overrun if the boiler has been firedpreviously.

Check that the pilot gas cocks and electrical supplyare turned off.

Set the boiler control thermostat to the requiredposition and the time clock to the ‘ON’ position. Checkthat the high limit thermostat has not been tripped byremoving the hexagon cap nut and pressing thebutton beneath it.

Start the boiler by switching on the main isolator andthe on/off switch on the boiler control panel fascia andthe boiler will attempt to light. After a delay (pre-purgetime) of approximately 40 seconds the ignition sparkshould be heard and after 5 seconds the control boxshould lock out.

If the ignition spark is not detected or the control boxdoes not lock out see Fault Finding

Commissioning Live Run

1 Turn on the appliance isolation valve.

2 Check the inlet pressure, which should be at least20mbar, on the inlet test pressure point and notethe value.

3 Close the pilot supply gas cock and check that thepilot pressure is zero and not moving.

4 Turn on the electricity supply at the main isolatorand at the on/off switch on the control panelfascia, (ensuring that time clocks and any otherexternal controls are made or are in the ONposition) also turn on the pilot isolating valve.

5 Approximately 40 seconds (pre-purge time) afterswitching on the ignition a spark should appearfollowed by ignition of the pilot burner. If the pilotflame is not established the control box willlockout in approximately 5 seconds..

6 The control box may be reset after a delay of fiveseconds by pressing the reset button on thecontrol panel and the red light will go out. Whenthe pilot flame is established check the gaspressure on the gas manifold pressure nipple andadjust the regulator if necessary (located on thegas valve). Turn off the pilot check valve and pulloff the ionisation probe and check that the pilotand main burner shuts down.

7 Re-connect the ionisation probe and tune on thepilot check valve and the pilot burner will relightfollowed 10-15 seconds later by the main gasburners.

8 Observe the main gas flame through the viewingport above the pilot burner, the flames should be

blue and well defined ‘V’ shaped flame. Thencheck the main gas manifold gas pressure andadjust to give correct burner pressure

9 For high/low operation the high fire rate must be set first.

With a pressure gauge fitted to the burnermanifold, turn the boiler on and set the gas valve.

Before any adjustment can be made the yellowcap must first be removed.

Adjust the high fire adjustment screw using an8mm spanner to turn the adjustment screw,clockwise to increase and anti-clockwise to reduceuntil correct high fire burner pressure is reached.

The low fire rate can now be adjusted by adjustingthe low fire adjustment screw using a screwdriver(clockwise increases and anti-clockwise reducesthe low fire burner pressure) until a low fire burnerpressure is reached.

Operate the boiler at high and low fire checkingthat the burner manifold pressure is correct andthat the flame is stable and blue.

10 Test the gas connection between the ignition valveand the pilot burner for soundness with a soapsolution or other approved method and seal anyleakages. Switch off the electrical supply andcheck that the burner has extinguished. Removethe pressure gauge from the burner manifold andreplace the sealing screw.

11 Check the reliability of ignition of the boiler byswitching the boiler off using the burner on/off switch on the boiler control panel. After two

minutes turn the switch back on. The boiler will now relight. Check that the pilot has a stable flame and that the main burners light smoothly.

12 With the boiler switched on test for soundnessbetween the gas valve and the burner manifoldwith a soap solution or any other approvedmethod and seal any leaks.

13 Turn the appliance isolation valve off. The mainand pilot burners should go off. The boiler willattempt to relight. Check that the ignitor startsand that the boiler locks out.

Gas Valve Arrangement

Single stagevalveDO NOT adjust

Pressureswitch

ValveAdjustmentunder Cap



Fig. 21A – Honeywell VR4601Q Gas Valve

Ionisation Current Check

Switch the boiler off at its on/off switch and at themain isolator. Connect a micro ammeter into theionisation cable in between the electrode and cable.Switch on the main isolator and the burner on/offswitch and after 15 seconds the ignition spark shouldbe heard followed by lighting of the pilot burner. Themicro ammeter should read approximately 3 - 4µA.

Switch off the main isolator and the on/off switch andremove the micro ammeter connections.Ventilation Checks

For boiler houses with natural ventilation, the area ofthe grilles should be checked against the notes givenon Ventilation in Section 3.

For boiler houses with mechanical ventilation, thesuitability of the ventilation and extract system shouldbe checked against the notes given on MechanicalVen ilation in Section 3.

In posven

THWIT

Op

Afteme

be checked.

To Shut Down Boiler

1 Temporarily - Switch the on/off switch to "OFF".Switch off the electrical supply.

2. Long Periods - As above but in addition turn offthe service cock at the gas meter.

Boiler Maintenance

It is essential for efficient and trouble free operationthat the boiler plant is regularly maintained. This mustbe carried out by qualified and experienced engineersand in the case of gas fired appliances attention isdrawn to the mandatory requirement of CORGI(Confederation of Registered Gas Installers)registration of personnel undertaking work on theseappliances. This facility is available from PottertonCommercial Division, details are available fromRegional Offices listed on the back page back of thismanual.

Boilers should be serviced and re-commissioned as aminimum on an annual basis but frequency maydepend on usage and application of the boiler.

It is strongly advised that a maintenance contract beentered into with Potterton Commercial Division toensure that the boiler/burner unit is correctly andproperly maintained.

WARNING Isolate the electrical and fuel suppliesb fore attempting any maintenance work.

Following completion of maintenance on the boiler theboiler should be re-commissioned.Boiler Cleaning

At every service visit the boiler should be cleaned asdetailed below and the soundness of the gas controlassembly must be checked. The boiler should be fullyre-commissioned as described below with attentionalso paid to -

1 The effectiveness of natural and mechanicalventilation and in particular the safe operation of

CapAdjustment screw forHigh Fire

Valve Adjustment underCap

t

addition, the installer must check that it is notsible for the boiler to operate if either thetilation or extract fans are not running.

E BOILER SHOULD NOT BE OPERATEDHOUT ADEQUATE VENTILATION.

eration Of Ancillary Controls

r lighting the boiler the operation of the aboventioned controls, eg. clock and thermostats, should

2

3

4

.

e

an air flow switch on a mechanical ventilationsystem.

That the chimney system is sound andadequately evacuating the products ofcombustion and that there is no spillage of flueproducts.

That the burner gas pressure is correct and thatthe boiler is still on rate.

That the low pressure switch on a booster



system, if fitted, is operating correctly.

5

Tbds

1

2

3

4

5

DM

R

R

That the water flow switch, if fitted, is operatingcorrectly.

o clean the boiler it will be necessary to remove theoiler flue hood cover and burner assembly asetailed below. Ensure boiler is isolated from allupplies.

Remove the boiler door by lifting forward andupwards (disconnect earth wiring and chain).

Disconnect the gas union, which is located abovethe gas valve.

Unscrew the 6 nuts on the burner fixing plate onthe right and left hand sides.

Disconnect the spark ionisation and earth wires
to the pilot burner.
Pull the burner assembly forward and clean theburner, pilot burner and combustion chamber ofdust and debris

Top Panel Removed & Access to 2nd Heat Exchanger

ismantling the Secondary Heat Exchanger forain Heat Exchanger Cleaning.

emove Rear Cover

emove Top Panel

Rt

emove the front part of the hood to allow access tohe main heat exchanger.



Access to the main heat exchanger by removing theperforated plate

Loosing the nuts for 2nd heat exchanger removal

Disconnect the water supply and return connection tothe secondary heat-exchanger.

Disconnect the fan, damper and duct by loosening thenuts on the rear flange

Remove the whole assembly

With the flue brushes provided clean the flueways ofthe cast iron heat exchanger if necessary.

Following completion remove the debris from thebottom of the boiler.

Following completion of the above the boiler shouldbe reassembled. The integrity of the gaskets andinsulation should be checked and replaced ifnecessary during re-assembly.

Clean the burner bars and ensure that the holes/slotsare clear. If necessary blow the slots and internalsclear with compressed air or soft brush and vacuum.

On no account should the burners be wire brushed.

After re-assembly test for gas soundness as detailedunder Commissioning and check the burner manifoldunion and pilot burner union for gas leaks.

Access to fan, pressure switches, dampers andventuri.

Air Pressure Switches

Rear part of the secondary heat exchangerDifferential pressure connections connected to the airpressure switches.



WATER FLOW SWITCH

For boilers fitted with a water flow switch, the installershould check that it is not possible for the boiler toflow when there is no water flow. This may be done bychecking the boiler closes down when the pumps areswitched off or the water flow is gated off. Alwaysrestore the water flow before completingcommissioning.

FAULT FINDING

Set out below are general guidance notes on systemfault finding.

Overheat Operation

Operation of the boiler overheat thermostat isassociated with a reduction in boiler water flow.Where overheat operation is reported the followingshould be checked.

a) The boiler/system pump has not tripped.

b) Pump overrun is operational to dissipate residualheat from the boiler on system shut down.

c) System valves are open.d) The boiler is operating at the correct rate and is

not overfired.

To reset the overheat thermostat allow the boiler tocool down, remove the overheat thermostat knob andpress the reset button.

The use of a primary loop system is highlyrecommended to provide a constant boiler flow rateunder all operating conditions.

Burner Lockout

The boilers have an integral safety system to allow thesafe and reliable operation of the burner. Failure ofthe burner to operate correctly will cause the burnercontrol box to "lockout" and the lockout button on theburner will illuminate to indicate this.

The lockout condition can be manually reset bypushing the reset button and the control box shouldrestart its control sequence in an attempt to light the

burner. If the control box lockout will not reset or goesto lockout after being reset then the services of aboiler repair/maintenance company should be sought.This service is available from Potterton CommercialDivision service offices at the addresses on the backpage of this manual.

WARNING: The lockout reset button should not berepeatedly operated otherwise a hazardoussituation may occur.

Should the boiler go to lockout, check the followingbefore attempting to relight the burner.

1 The gas meter pressure is above 18 mbar.

2 The electrical supply to the appliance is of thecorrect voltage and polarity.

General Arrangement of Pilot Burner

Earth

18.5mm

7mm

3-4 mm

IonisationElectrode

IgnitionElectrode



Fault Finding

Stage 1

Boiler does not attemptto light.

Control box does notlockout.

a) Check electricity supply is available to boiler and mains LED is illuminated.

b) Check the boiler is being called to operate.

c) Check overheat cut off device has not operated.

d) Check power supply is available to control box (see wiring diagram). Replace box iffaulty.

e) Check burner overheat cut-off has not operated

f) Check secondary heat-exchanger overheat cut-off has not operated

g) Check gas supply

Stage 2

Boiler does not attemptto light even with the fanrunning

a) Check the air pressure switch for low load

b) Check that the air pressure switch tube is not blocked

c) Check the integrity of the differential air pressure switch after the fan

d) Check the cleaning of the secondary and primary heat-exchangers

e) Check the damper position

f) Check the rheostat positionStage 3

No ignition spark.

Pilot does not light.

Control box goes tolockout.

a) Check ignition electrode continuity for earth fault, check the ignition wire.

b) Check power supply is available to electronic ignitor during ignition period

c) Check operation of ignitor. Replace if necessary.

Stage 4

Ignition sparks.

Pilot burner does notlight.

Control box locks out.

a) Check gas supply is available at the pilot burner at the correct pressure.

b) Check gas supply is purged of air.

c) Check pilot injector.

d) Check ignition electrode position.

Stage 5

Pilot burner lights.

Control box goes tolockout after 10 seconds.

a) Check electrical supply polarity.

b) Check earth continuity to pilot burner.

c) Check pilot burner pressure is correct.

d) Check there is no earth leakage on ionisation probe circuit.

e) Check ionisation probe circuit for correct flame current. This is achieved byconnecting a DC micro ammeter in series. A reading of at least 3 to 4µA DC shouldbe obtained. If this is obtained and the control box continues to lock out then replacethe control box.



Stage 6


Main burner does notlight.

Control box does notlockout.

a) Check main burner gas valve is open.

b) Check electrical continuity to main gas valve.

c) Check operation of gas valve and replace if necessary.

d) Check control box. Replace if necessary.

Stage 7


Main burner lights.

Control box locks out.

a) Check ignition of main flame is smooth and reliable.

b) Check voltage supply for interference.

Stage 8

Boiler works on low loadonly

a) Check the 230V supply

b) Check the damper position

c) Check the main gas valve adjustment at 16.5 mbar

d) Check the air pressure switch for full load

e) Check the rheostat positionStage 9

Boiler work on high loada) Check the main gas valve to be at 10.5 mbar



Rheostat

2nd stage control thermostat

AP1

P-CH

AP2

VMB2VMB1

LFil bleu

Fil jaune/vertP

TR2

IONZP

Air pressure switch 1st stageAir pressure switch 2nd stage1st step indicator light2nd step indicator lightBoiler pump

Blue wire : neutral

Flame ionisation probe

Gas pressure switchYellow/green wire : earth

Live

Pump switch

ZSB

MST

TR1

TR

VSCVSB

ZTF1

TSBDGAI

STBTF

Burner reset

Safety mode thermostat

Flame failure indicator lightMains indicator light

1st stage control thermostat

Overheat indicator light

Burner test switchFuse

Burner control systemSafety burner thermostat

Overheat thermostatFlue thermostat



Spare Parts List - Casing

Ite123455566677788899910101011111112

m No. Description Qty Part NoLeft hand side panel assembly 1 S137730ARight hand side panel assembly 1 S137731ARight hand side front panel assembly 1 S136416BBLeft hand side front panel assembly 1 S136415BBFront door (4 sections) 1 S137958AFront door (6 sections) 1 S137959AFront door (8 sections) 1 S137960AFront top panel (4 sections) 1 S136431AFront top panel (6 sections) 1 S136432AFront top panel (8 sections) 1 S136434AInsulation board (4 sections) 1 S136449HInsulation board (6 sections) 1 S136450HInsulation board (8 sections) 1 S136452HControl panel assembly (4 sections) 1 S136920HControl panel assembly (6 sections) 1 S136921HControl panel assembly (8 sections) 1 S136923HCondensor casing assembly (6 sections) 1 S137732ACondensor casing assembly (4 sections) 1 S137733ACondensor casing assembly (8 sections) 1 S137734ARear top panel assembly (6 sections) 1 S137752ARear top panel assembly (8 sections) 1 S137753ARear top panel assembly (4 sections) 1 S137754ABack panel (6 sections) 1 S137546Back panel (8 sections) 1Back panel (4 sections) 1 S137701Side panel insulation 1 S131804



Item No. Description Qty Part No13 Condensor casing front panel insulation (6 sections) 1 S13773913 Condensor casing front panel insulation (8 sections) 1 S13774013 Condensor casing front panel insulation (4 sections) 1 S13774114 Rear top panel insulation (8 sections) 1 S13774914 Rear top panel insulation (6 sections) 1 S13775014 Rear top panel insulation (4 sections) 1 S13775115 Condensor casing side panel insulation (4-6 sections) 2 S13773715 Condensor casing side panel insulation (8 section) 2 S13773816 DGAI 73 MOD 10.3.30 TCL-Z 1 S50375517 Wire-wound rheostat 25W 1000R 1 S50375717a Rheostat locking system 1 S50401618 Fan capacitor (4-6 sections only) 1 S13775719 Timed delay relay OMRON H3DS-AL 1 S50375620 Relay LY2F 220AC 1 S1581504921 Rheostat support 1 S13786822 Rheostat + relay support assembly (4-6 sections) 1 S13775823 Wiring assembly 1 S13740424 Control board (4 sections) 1 S13769824 Control board (6 sections) 1 S13796924 Control board (8 sections) 1 S13797025 Fixing brace 2 S13776926 Bag of fixing screws 1 S504412



Heat Exchanger Assembly

Item No. Description Qty Part No1 Left Hand Section 1 S178008572 Right Hand Section 1 S178008473 Intermediate Section 1 S178040574 Flow Header (4 Sections)

Flow Header (6 Sections)Flow Header (8 Sections)

111

S501407S201409S501411

5 Manifold Clamp Plate (4 Sections)Manifold Clamp Plate (6 Sections)Manifold Clamp Plate (8 Sections)

111

S131164S131166S131168

6 Extension 526 ½” L.50 1 S159227057 Bleed Tap ½” 1 S170064728 Flow Pipe (4 Sections)

Flow Pipe (6-8 Sections)11

S17004722S17004723

9 Elbow 1½” (6-8 Sections)Elbow 1¼” (4 Sections)

11

S9125780S15923012

10 Side Case Fixing Panel (6 Sections)Side Case Fixing Panel (8 Sections)Side Case Fixing Panel (4 Sections)

111

S131317S131326S137922

11 Rear PanelRear PanelRear Panel

111

S137636S137692S137703

12 Rear Panel Insulation (6 Sections)Rear Panel Insulation (8 Sections)Rear Panel Insulation (4 Sections)

111

S137745S137746S137929

13 Front Insulation (8 Sections)Front Insulation (6 Sections)Front Insulation (4 Sections)

111

S131812S131814S137932

14 Oburating Insulation 1 S133107

48 Bag of Fixings



15 Insulation Strip (8 Sections)Insulation Strip (6 Sections)Insulation Strip (4 Sections)

111

S132564S132566S132568

1616a

Thermostat PocketSpring Ref. 556557

11

S17001781S17006459

17 Cap No.290 ¼” 8 x 13 1 S1592600418 Base Tray (8 Sections)

Base Tray (6 Sections)Base Tray (4 Sections)

111

S137586S137587S137767

19 Seal 24 x 16 x 3 – Blue 1 S50113920 Pipe Clip Retaining Plate 1 S13273521 Pipe Clip 1 S13281422 Electronic Transformer Support 1 S13177723 Jump Lead SIHT-VS 1.4 mm 1 S1582523024 Ignition Cap 1 S50048325 Transformer Wiring 1 S13240626 Ceramic Felt Strip 30 x 3 3m SN920535027 Ceramic Felt Strip 20 x 3 3m SN920532028 Ceramic Sealing Strip (6-8 Sections)

Ceramic Sealing Strip (4 Sections)1.50m1.50m

SN9195370S17000167

29 Tie Bar M10 x 450 (6 Sections)Tie Bar M10 x 610 (8 Sections)Tie Bar M10 x 300 (4 Sections)

111

SN9170990SN9171010S15243610

30 ‘O’ Ring Seals 1 SN919522031 Studs M10 x 120 1 S1524537232 4 Entries Cable Locking System 1 S1707633233 Strengthening Piece for Stability (4 Sections) 1 S13647834 Condensor Backflow Tube (6-8 Sections)

Condensor Backflow Tube (4 Sections)11

S137554S137563

35 Boiler Backflow Tube (6-8 Sections)Boiler Backflow Tube (4 Sections)

11

S137555S137562

36 Seal 30 x 22 x 2 GEB 2064 1 S1562524737 Diaphragm 15 dia.(4 Sections)

Diaphragm 16 dia. (6 Sections)Diaphragm 19 dia. (8 Sections)

111`

S137879S137880S137881

38 Seal BA-U 38 x 27 x 2 (4 Sections)Seal 44 x 32 x 2 (6-8 Sections)

11

S133221S15600310

39 Condensor Heat Exchanger (6-8 Sections)Condensor Heat Exchanger (4 Sections)Condensor Heat Exchanger (6 Sections)Condensor Heat Exchanger (8 Sections)

1111

S15600310S503498S503499S503500

40 Silicone Braid 7 dia. 1.50m S1700016641 Drain Cock 1 S1700619342 Cylindrical Link M-F 1 ¼” – ¾” 1 S13762743 Siphon 1 S50410044 + 46 Flexible Tubing ¾” – 1” L.960 (4-6 Sections)

Flexible Tubing M-F 1” L.960 (8 Sections)11

S137560S137557

45 + 47 Flexible Tubing ¾” – 1” L.1160 (4-6 Sections)Flexible Tubing M-F 1” L.1160 (8 Sections)

11

S137561S137558

48 Bag of Fixings 1 S504285



Fan Assembly

IN1

2

3

4

5

6

7891

1

1

1111

111

temo.

Description Qty Part No

Connecting Piece for Fan (4-6 Sections)Connecting Piece for Fan (8 Sections)

11

S137526S137571

Fan G2E 120-ML07-12 (4-6 Sections)Fan G2E 120-DD70-09 (8 Sections)

11

S17004925S503501

Exhaust Gas Device (6 Sections)Exhaust Gas Device (8 Sections)Exhaust Gas Device (4 Sections)

111

S137533S137552S137570

Fan Wiring (4-6 Sections)Fan Wiring (8 Sections)

11

S504137S504138

Air Pressure Switch 604.9040030W34/20 (4 Sections)Air Pressure Switch 604.9040030W34/50 (4 Sections)

11

S504014S504015

Air Pressure Switch 604.9140030W427/150 (6-8 Sections)Air Pressure Switch 604.9140030W427/400 (6-8 Sections)

11

S503792S504013

Klixon US603UXTFSPH100 +/- 4ºc 1 S502259Thermostat Wire 1 S137988Axis 1 S137887

0 Damper (6-8 Sections)Damper (4 Sections)

11

S137721S137891

1 Fan/Seal (8 Sections)Fan/Seal (4-6 Sections)

11

S137572S138248

2 Bolt M4Bolt M4 x 18 Stainless Steel

44

S137719S137772

3 Wieland Connector Support 1 S1377294 Air Pressure Switches Support 1 S1379005 Venturi 1 SX54070506 Fan/Seal (4-6 Sections)

Fan/Seal (8 Sections)11

S137553S137573

7 YS6 (NORMA) 2 S1377208 Silicon tube 5/8 Ø (not shown) 1 S5042369 Screw Fixings – bag of screws (not shown) 1 S504409

18 Silicon Tube Ø5/819 Screw Fixings



Flue Box Assembly

6IN1

2

3

4

6

7

8

9

4IN1231111

& 8 Sectiontemo.


Welded Flue Box Assembly (6 Sections)Welded Flue Box Assembly (8 Sections)

11

S137507S137517

Flue Box Front (6 Section)Flue Box Front (8 Section)

11

S137500S137514

Trap for Cleaning (6 Sections)Trap for Cleaning (8 Sections)

11

S137502S137518

Flue Box Perforated Plate (6 Sections)Flue Box Perforated Plate (8 Sections)

11

S137647S137648

Left Hand Side Flue Box Insulation (6 Sections)Left Hand Side Flue Box Insulation (8 Sections)

11

S137857S137860

Right Hand Side Flue Box Insulation (6 Sections)Right Hand Side Flue Box Insulation (8 Sections)

11

S137856S137859

Front Side Flue Box Insulation (6 Sections)Front Side Flue Box Insulation (8 Sections)

11

S137855S137861

Back Side Flue Box Insulation (6 Sections)Back Side Flue Box Insulation (8 Sections)

11

S137858S137862

Sectiontemo.


Welded Flue Box Assembly (4 Sections) 1 S137670Flue Box Front Panel (4 Sections) 1 S137667Trap for Cleaning (4 Sections) 1 S137666

0 Right Hand Side Flue Box Insulation (4 sections) 1 S1378511 Left Hand Side Flue Box Insulation (4 Sections) 1 S1378522 Top Flue Box Insulation (4 Sections) 1 S1378523 Back Side flue Box Insulation (4 Sections) 1 S137854

6 & 8 Section

4 Section



GeneralItemNo.


5 Ceramic Felt Seal 20 x 3 3m SN920532014 Flue Securing Plate 30 x 40 1 SN918006015 Wing Nut M8 x 20 1 SN917018016 Bag of Fixings 1 S504306



Burner Bar Assembly

Item No. Description Qt1 (notshown)

Burner Bar Assembly Condensing 8 Sections UKBurner Bar Assembly Condensing 4 Sections UKBurner Bar Assembly Condensing 6 Sections UK

111

1a Burner Mounting Plate 6 SectionsBurner Mounting Plate 8 SectionsBurner Mounting Plate 4 Sections

111

2 Burner Bar 120/70 LG4 16 13 Burner Back Plate 4 Sections

Burner Back Plate 6 SectionsBurner Back Plate 8 Sections

111

4 Mounting Plate Insulation 8 SectionsMounting Plate Insulation 4 SectionsMounting Plate Insulation 6 Sections

111

4a Top Insulation 4 SectionsTop Insulation 6 SectionsTop Insulation 8 Sections

111

4b Side Insulation 25 Gas Manifold 6 Sections

Gas Manifold 4 SectionsGas Manifold 8 Sections

111

6 Burner Injector 77 Injector Washer 78 Tap Mini FF 1/8 Cv. Cr.0T58 18a Elbow for 4 dia. Tube 18b Conical Tap Connection B1 19 –9a Gas Valve Manifold + Gas Valve Seal 210 Nut G H 8 x 50 ABIG 610a Washer D 38.5/8.5 6

19A
1 Burner Bar Assembly24 Pilot Assembly34 Gas Supply Pipe Assembly
y Part NoS137589S137684S503791S137179S137181S137683S9020400S132465S132806S133742S137030S137032S137034S135625S135627S135629S137100S137580S17006493S17006497S174003180S17006504S17006461S136479S1333831S1700630215236109SN9184110



11 Gas Valve Honeywell VR46011QB2019 1 S50283411a Adapter Screw 45.900.428-003 1 S50317312 Gas Valve Honeywell VR4605CB1009 (6-8 Sections) 1 S50043313 Honeywell Wiring Assembly 1 S13239114 Gas Valve Tube (4 Sections) 1 S13300415 Second Gas Valve Wiring (6-8 Sections) 1 S13646516 Quad-Ring Seal 25 dia. (6-8 Sections) 2 S1563011017 Gas Valves Tube (8 Sections)

Gas Valves Tube (6 Sections)11

S131731S137581

18 Inspection Glass 147.125.002 1 S13758119 Pilot Tube (4 Sections)

Pilot Tube (6 Sections)Pilot Tube (8 Sections)

111

S137621S137623S137625

19A Burner Manifold Test Nipple 1 S1700620120 Pilot Tap Tube 4/2 1 S13648421 Pilot Tube Connection 4mm 1 S50283523 Klixon US603UXTFSOH100 +/-4ºC 1 S50225923a TSB Wiring 1 S13681824 Pilot Assembly 1 S13713224a Pilot 1 S13713125 Sparking Plug 1 S13425726 Ionisation Plug 1 S13396527 Pilot Brace 1 S1700211028 Pilot Injector 1 SN559036029 Seal BA-U 38 x 27 1 S13322130 Gas Supply Pipe 1 ¼” 1 S13268631 Elbow No.90 1 ¼” 33 x 42 1 S1592301232 Column for Gas Pressure Switch 1 S13323033 Gas Pressure Switch GW50 A5 1 S1700602534 Gas Supply Pipe Assembly 1 S13270635 Bag of Fixings for Condensing Burner Assembly 1 S504411



Control Panel

I122334561111111111122223

tem No. Description Qty Part NoFront Panel 1 S137535Counter Mask FMG-GMG 1 S17002268

a Thermometer Mask R3 1 S17002281Rear Panel 1 S137874A

a Bolt DZUS 1 S504314Front Panel Support 1 S137873HControl Panel Casing 1 S504313Cable Terminal Support 1 S136979

0 Thermostat TXA4C 019 1 S170070041 Thermostat Lever 1 S170047382 2a

Fuse SupportFuse TFS 5 x 20 6.3A

11

S15803999S15803525

3 Bag of Lights 1 S5019704 Bag of Switches 1 S5030815 Thermostat TG400 Cap.2m 1 S170069556 Thermostat 68.5 x 14.5 0-120º 1 S1344217 CB120 Module Front Panel 1 S1371588 Relay LY2F 220AC 1 S158150499 Time Delay Relay OMRON H3DS-AL 1 S50375600A

Basic CB 129 Module AssemblyBasic CB 120 Module Wiring

11

S137157S136811

11A

CE 100 Module AssemblyCE 100 Module Wiring

11

S137160S136412

0 Mask G.M.AVA 30.200/109 1 S17000983

REPORT SENT TOINSTALLER: YES NO

DATE:

SIGNATURE:

REPORT No: INSTALLER NAME & ADDRESS:SITE ADDRESS:

COMMISSIONING DATE:

COMMISSIONING REPORT

Brooks House, Coventry Road, Warwick, CV34 4LL.Tel: (08706) 050607 Fax: (08706) 001516

1.0 BOILER1.1 Type:1.2 No. of Sections:1.3 No. of Boiler/position1.4 Serial No.1.5 Fuel: N/Gas LPG

2.0 BURNER/CONTROLS2.1 Type: Atmospheric Pre-Mix

2.2 Flame DetectionProbe: UV Cell Thermocouple

2.3* Control Box Type:2.4 Electrical Supply:2.5 Main Gas Valve Type & Size:2.6 Pilot Gas Valve Type & Size:2.7 Gas Train Serial Number:2.8 Gas Booster Type & Size:2.9 Gas Booster Serial No:3.0 BURNER SETTINGS3.1 Main Burner Injector Size mm3.2 Pilot Burner Injector Size mm3.3 Electrode Setting

(to manufacturers instructions) mm

3.4* Ionisation Probe Setting(to manufacturers instructions) mm

3.5 Are Burners & Injectors Clean4.0 FLUE SYSTEM CHECK Yes No N/A

ConventionalFan Assisted

Fan Dilution System

Monodraught System

4.1 FlueType

Plant Room Door Interlocked4.2 Draught Stabiliser Fitted4.3 Dampers Fitted4.4 Fan Assisted Ventilation4.5 Fan Interlock Checked4.6 Is Flue System Clear4.7 Flue Header Diameter mm4.8 Stack Diameter mm4.9 Approximate Overall Height of Flue M

5.0 PRE-COMMISSIONING PRELIMINARYCHECKS (See Notes) Yes No N/A

5.1 Is boiler house ventilation as per therelevant B.S.

5.2 Electricity supply fused, isolated & earthwire connected.

5.3 Check external controls allow operation

5.4 Check boiler/system filled and pumpsoperational & any isolation valves open

5.5 Check gas available at burner5.5 Check gas available at burner5.6 Check oil available at burner

5.7 Check gas meter fitted & sizedadequately

5.8 Check that gas pipe has been purged.

6.0 COMBUSTION Pilot Low High Unit6.1 Inlet Gas Supply Pressure

(Boilers running)mbar

6.2 Burner Pressure mmwg

6.3 Gas Rate m3/hr6.4* Ionisation Probe/UV Cell Current6.5c Air Shutter Position ----6.6 O2 %6.7 CO2 %6.8 0CO ppm6.9 Gross Flue Gas Temperature oC

6.11 Ambient Temperature oC6.12 Flue Draught mm

wg6.13 Burner Fan Static Pressure mmwg

7.0 OPERATIONAL SAFETY CHECKS7.1 Check Control Thermostat Operation7.2 Check Limit Thermostat Operation7.3 Check High/Low Thermostat Operation7.4 Check For Gas Leaks7.5 Check For Gas Leakage Past Valve Assembly7.7* Check Boiler Locks Out On Loss Of Flame Signal7.8 Check boiler Locks Out On Air Pressure Switch

Operation7.9 Check Boiler Locks Out On Gas Inlet Pressure

Switch7.10 Check Boiler Locks Out On All Other Safety

Functions7.11 Check For Flue Sillage7.12$ Check Thermocouple Operation7.13$ Check Thermocouple Interrupter Operation7.14 Check Gas Booster Interlock Operational

Record INLET and OUTLET Pressure Switch Settings:-

INLET……………………… OUTLET………………………….

8.0 BOILER/SYSTEM CHECK LIST8.1 Control Thermostat Setting OC8.2 High/Low Thermostat Setting OC8.3 Maximum Flow Temperature Recorded OC8.4 Maximum Return Temperature Recorded OC8.5 Boiler Water Pressure8.6 Are Pipework Connections As Per Manual

Is Safety Valve FittedIf So, SIZE:-…………………………..…………. PRESSURE RATING…………………...

YES NO8.8 Are Water Isolating Valves Fitted8.9 Are Water Flow Switches Fitted

8.10 Are Return Water Shut Off Or DiverterValves Fitted

8.11 Is Shunt Pump Fitted8.12 Is Pump Overrun Fitted

NOTE: 6.6, 6.7 & 6.8 to be measured in secondary flue 600mm upfrom the flue socket or at the sampling point provided.Normally 6.12 and 6.13 are recorded when tapings provided.Position of measurement to be in accordance with boiler and/orburner manufacturers instructions.

* Fully Electric Boilers$ Thermo-Electric Boilersc Condensing Boilers

10.0 NOTES & COMMENTS BY COMMISSIONINGENGINEER

FINDINGS

YES NO

Is The Installation Safe For Use?

If The Answer Is NO Has A Warning Label BeenRaised?Is Any Remedial Work Required?

Have Warning Labels Been Fitted?

Has RIDDOR Form Been Raised?

CUSTOMER SIGNATURE:-

PRINT NAME:-

DATE:-

ENGINEER DETAILS

NAME

COMPANY

SIGNATURE DATE

Flue Type & Diameter Of Connection To Boiler:-

TYPE…………………………../DIAMETER(mm)……………..

Where appropriate and for multi boiler installations sketch.details of flue system showing length of runs and diameter

Conventional Fan Assisted Flue Dilution

8.13

Approximate Overall Height………………………………m

YES NO8.14 Is The Fan Interlocked With The Boiler?

8.15 Are Flue Dampers Fitted?If So Are They Interlocked?

8.16 Fan Assisted Ventilation?8.17 Any Evidence Of Condensate Formation?8.18 Any Evidence Of Water Leakage?8.19 Any Evidence Of Flue Gas Leakage?8.20 Has Boiler Been Built And Cased Correctly?

8.21 Is Gas Service Cock Installed?If So Is It Accessible?

9.0 REPAIRS CARRIED OUT

COMMISSIONING REPORT (Continued)

Note: It is the installer’s responsibility to ensure that the boiler is correctly commissioned by a competent engineer and that this report iscompleted as a permanent record. A commissioning service is available from Potterton Commercial at the address listed on the back page ofthis manual. When a Potterton Commercial engineer commissions the boiler this commissioning report will be filled in and left with the boiler.Commissioning by Potterton Commercial engineers is restricted to equipment of our supply. No responsibility will be accepted for the on siteassembly or installation of the equipment unless specifically carried out by Potterton Commercial. The installer must ensure that the boiler isinstalled in accordance with the manufacturers instructions and all relevant B.S, Codes of Practice and Regulation. (see manufacturersinstructions for full details) Item 5.1 to 5.8 are related to the boiler instructions and as such these pre-commissioning check should be carriedout in the presence of the installer.

PCF No. 207/03
Baxi Heating Ltd. Registered Office:Sir Frank Whittle Road, Derby DE21 4XARegistered in England No. 3879156

CONVERSION TABLE

IMPERIAL TO METRIC METRIC TO IMPERIALHEAT 1 Btu/hr = 0.291 W 1 kW = 3412Btu/hr1 Therm = 100,000 Btu/hr 1 Btu = 1055 J 1 J = 0.0009478 Btu

1 Btu/hr = 0.252 kcal/hr 1 kcal/hr = 3.968 Btu/hr

FUEL CONSUMPTION 1 ft3 = 28.317 dm3

(litre) 1 m3 = 35.3147 ft3

1 dm3 = 1 LITRE 1 UK Gall = 4.546 litre 1 litre = 0.2199 Imp1,000 dm3 = 1 m3 1 UK Gall = 1.2 U.S. Gallon 1 U.S. Gallon = 0.83 UK GallonPRESSURE 1 lb/in2 = 6895 Pa 1 bar = 33.45 ft.w.g1 PSI = 2.307 FT 1 lb/in2 = 68.95 mbar 1 kPa = 0.3345 ft.w.g1 kPa = 1000 Pa 1 in.w.g = 249.1 Pa 1 bar = 14.5 lb/in2

1 bar = 1000 mbar = 100 kPa 1 in.w.g = 2.491 mbar 1 Pa = 0.358 in.w.g1 in.w.g = 25.4 mm.w.g 1 mm.w.g = 0.0394 in.w.g

1 mm.w.g = 9.8 PaLENGTH 1 inch = 25.4 mm 1 mm = 0.03937 in1m = 1000mm 1 ft = 0.3048 m 1 m = 3.281 ft

1 yard = 0.9144 m 1 m = 1.094 yard1 mile = 1.609 km 1 km = 06214 mile

VOLUME 1 ft3 = 0.02832 m3 1 m3 = 35.3147 ft3

1 ft3 = 28.32 litre 1 litre = 0.03531 ft3

AREA 1 in2 = 645.2 mm2 1 mm2 = 0.00155 in2

1 in2 = 6.452 cm2 1 cm2 = 0.155 in2

1 ft2 = 929 cm2 1 m2 = 1550 in2

1 ft2 = 0.0929 m2 1 m2 = 10.76 ft2

FLOW RATE 1 gall/min = 0.7577 lit/sec 1 lit/sec = 13.2 gall/min1 kg/sec = 1 lit/sec @ 0°C 1 ft3/min = 0.4719 lit/sec 1 lit/sec = 2.119 ft3/minReference temperature 1 ft3/min = 0.00047 m3/sec 1 m3/sec = 2119 ft3/minTEMPERATURE °F to °C = (“X”°F-32) x 0.5556 °C to °F = (“X”°C x 1.8) + 32TEMPERATUREDIFFERENCE1°C = 1°K

“X”°F x 0.5556 = °C “X”°C x 1.8 = °F

WEIGHT 1 lb = 0.4536 kg 1 kg = 2.205 lb1 cwt = 50.8 kg 1 tonne = 0.9842 ton1 ton = 1016 kg 1 tonne = 2204.6 lb

Commercial SalesTechnical and Service Enquiries

Potterton Commercial

Brooks HouseCoventry RoadWarwick CV34 4LL

Tel: 08706 050607Fax: 08706 001516Sales Hotline: 08706 001991Technical Helpline: 08706 002322Service Hotline: 08702 412759e-mail: [email protected] site: www.pottertoncommercial.co.uk

Spares

Potterton Commercial spares are available nationwidethrough the interpart network of approved stockists.Alternatively please contact:-

interpartBrooks HouseCoventry RoadWarwickCV34 4LL

Tel: 08706 000454Fax: 08706 000545

Applications and Installations

Our experienced technical and applications team areavailable to offer advice on any aspect of heatingsystem design and boiler installation.

Please contact:

Tel: 08706 002322

Commercial Service

Our service organisation covers the whole of the UKto look after your needs for all Potterton Commercialproducts. We are also able to offer our services forother manufacturers products.

Our service department offers a wide range ofspecialised services including:-

Boiler site assembly Burner commissioning for all fuels Boiler maintenance and maintenance contracts Breakdown and repair services Boiler dismantling and re-jointing Burner and boiler replacement Oil/gas conversions Systems conditioning Water treatment and descaling Packaged units

“All descriptions and illustrations contained in this leaflet have been carefully prepared but we reserve the right to makechanges and improvements in our product which may affect the accuracy of the information contained in this leaflet”

Registered Office: Pentagon House, Sir Frank W

h e a t I n g s p e c i a l i s t s

A Baxi Group Company

hittle Road, Derby DE21 4XA. Registered in England No. 3879156

Publication Number:M/COMPplus/0404

http://www.pottertoncommercial.co.uk/

may 2004 - the initiative · the potterton derwent compact plus condensing cast iron sectional...

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