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Potterton Derwent Compact Plus Installation, Operation & Maintenance Manual Download Page 30

POTTERTON COMMERCIAL PRODUCTS DIVISION

SECTION 7

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

DERWENT COMPACT PLUS - CONDENSING

PAGE 27

Heat Exchanger Assembly

Item No.

Description

Qty

Part No

1

Left Hand Section

1

S17800857

2

Right Hand Section

1

S17800847

3

Intermediate Section

1

S17804057

4

Flow Header (4 Sections)
Flow Header (6 Sections)
Flow Header (8 Sections)

1
1
1

S501407
S201409
S501411

5

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

1
1
1

S131164
S131166
S131168

6

Extension 526 ½” L.50

1

S15922705

7

Bleed Tap ½”

1

S17006472

8

Flow Pipe (4 Sections)
Flow Pipe (6-8 Sections)

1
1

S17004722
S17004723

9

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

1
1

S9125780
S15923012

10

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

1
1
1

S131317
S131326
S137922

11

Rear Panel
Rear Panel
Rear Panel

1
1
1

S137636
S137692
S137703

12

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

1
1
1

S137745
S137746
S137929

13

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

1
1
1

S131812
S131814
S137932

14

Oburating Insulation

1

S133107

48 Bag of Fixings

Summary of Contents for Derwent Compact Plus

Page 1: ...MAY 2004 ...

Page 2: ... 9 Boiler Main Components 9 Control and Safety Equipment 10 Working Principles 10 Hydraulic 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 5 Potterton Commercial Customer Commissioning Check List 12 contravention of regulations 12 commissioning 12 Page Control Panel 13...

Page 3: ... A B C D E ØF G H I Return Flow 4 456 1200 1050 1150 1130 182 157 81 87 1 1 6 537 1200 1050 1194 1140 202 197 45 51 1 1 8 699 1390 1255 1194 1140 252 283 45 51 1 1 B C Flow Return 1400 G ØF 263 I 874 H 868 D A E 1300 143 243 1004 Ø34 931 60 485 Gas Condensate Note Maximum Working Temp 90 C Maximum Working Pressure 3 Bar Electrical Supply 230V 50Hz 4 6 8 Water 1 1 1 Drain Gas 1 Table 2 Connections ...

Page 4: ...e on request CO2 NG 100 load 7 5 to 8 5 6 5 to 7 5 7 5 to 8 5 CO2 NG 80 load 6 5 to 7 5 6 5 to 7 5 6 5 to 7 5 Nominal Flue Connection Size Ømm 180 200 250 Flue Gas Volume m hr 95 175 235 Flue Draught Requirements mm 0 5 Flue Gas Temperature 60 80 C 100 C 63 73 80 Flue Gas Temperature 30 50 C 100 C 45 57 65 High Level Natural Ventilation to BS6644 cm 270 337 5 416 25 Low Level Natural Ventilation t...

Page 5: ...or expansion Sections 4 6 8 G 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 heat should be protected by an appr...

Page 6: ...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 out commissioning as this will make the LIFETIME GUARANTEE valid INSTALLATION The boiler should be installed in a clean boiler house free of dust and corrosive vapours During insulation of system ...

Page 7: ...stion clearances for service and access temperatures noise levels the disposal of boiler water and the effects of flooding of the boiler house or seepage from a roof top boiler house See page 4 for required boiler clearances for service and access A level non combustible floor capable of supporting the weight of the boiler filled with water see Table 3 together with any additional weight bearing d...

Page 8: ...y sweep or lobster back bend should be used FLUE SIZE CONSIDERATIONS Nominal flue connection sizes are given in technical data Table 3 these sizes refer to the boiler flue connection spigot The actual size of the flue system will depend on individual site applications Below are general considerations on sizing flue systems These notes are for guidance only and Potterton Commercial Division cannot ...

Page 9: ...sting systems where boilers are being replaced due to failure then the cause should be investigated before installing new boilers This can normally be achieved by cutting open a failed boiler section and examination for system debris or contamination Lime scale is a positive indicator of continuous system water make up due to water loss Evidence of magnetite black sludge in the system and the form...

Page 10: ...rk undertaken does not affect the electrical safety of the appliance In particular the earth connected to the buildings fixed electrical installation In the case of 1 above electrical work should only be undertaken once the boiler has been isolated from the electricity supply and confirmed electrically dead If this is impractical then suitable precautions must be undertaken to prevent injury In th...

Page 11: ...rior to attending site should be given 5 Sections casing etc should be kept in a clean and dry 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 all times 10 Clear instructions supplied to the persons carrying out the proposed work regarding positioning the boiler 11 Fire eva...

Page 12: ...on to the second stage operation Nominal load and remaining on this setting until the thermostat is satisfied The main valve with its regulator ensure the second stage operates correctly HYDRAULIC TEST OF BOILER This is to be carried out on boilers assembled on site or where water manifolds have been disturbed Fit a hydraulic test pump to the return manifold and fit a valve to vent air from the fl...

Page 13: ...e and repair The gas supply should be made through a suitable meter and the local gas undertaking should be consulted to determine the suitability of the meter and gas supply to meet existing and additional demands for gas The installation should be made in accordance with the requirements of the Gas Safety Installation Use Regulations and all other regulations and Codes of Practice In particular ...

Page 14: ... cause injury to personnel and damage to the boiler burner unit and could invalidate the manufacturer s warranties Commissioning should only be carried out by personnel approved and competent to do so This facility is available from Potterton Commercial Service Offices at the addresses as listed on the back page of this manual Before commencing to commission check the following 1 Electrical supply...

Page 15: ...gures should be taken with the boiler at high fire and a flow temperature of 80 C The combustion measurements should be taken in the secondary flue at a minimum of 600mm above the draught diverted GAS CO2 See Table 3 CO 0 50 ppm Flue Gas Temp See Table 3 Check and ensure that the boiler cable connections internally of the boiler are connected in accordance to the drawing below Ignition transformer...

Page 16: ... allowing control by the 1st Stage and 2nd Stage thermostats 9 6 3 Amp Fuse 10 Boiler Thermometer Gas Assembly 8 Section Model Shown The Gas Assembly is pre set at the factory ready for use at high and low conditions The 4 Section model has one main valve the 6 8 section have one main gas valve and one slave valve The main gas valve has a two stage governor for high and low load left valve The sla...

Page 17: ...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 the factory The installer has to verify the CO2 content by taking a reading in the flue between 200mm and 300mm from the top of the flue connection The Technical Data Table indicate the range acceptable The air can be re set by the damper on the inlet to the fan and a...

Page 18: ...GAS and ELECTRICITY supply to the burner should be IMMEDIATELY ISOLATED until such time that the fault has been investigated and rectified IMPORTANT After each adjustment gas flow rate and flue gas analysis should be re checked ALWAYS Use approved test equipment continually monitoring electronic equipment is recommended NEVER Rely on a visual inspection of the flame as a guide to combustion qualit...

Page 19: ...rner shuts down 7 Re connect the ionisation probe and tune on the pilot check valve and the pilot burner will relight followed 10 15 seconds later by the main gas burners 8 Observe the main gas flame through the viewing port above the pilot burner the flames should be blue and well defined V shaped flame Then check the main gas manifold gas pressure and adjust to give correct burner pressure 9 For...

Page 20: ...tenance It is essential for efficient and trouble free operation that the boiler plant is regularly maintained This must be carried out by qualified and experienced engineers and in the case of gas fired appliances attention is drawn to the mandatory requirement of CORGI Confederation of Registered Gas Installers registration of personnel undertaking work on these appliances This facility is avail...

Page 21: ...by lifting forward and upwards disconnect earth wiring and chain 2 Disconnect the gas union which is located above the gas valve 3 Unscrew the 6 nuts on the burner fixing plate on the right and left hand sides 4 Disconnect the spark ionisation and earth wires to the pilot burner 5 Pull the burner assembly forward and clean the burner pilot burner and combustion chamber of dust and debris Dismantli...

Page 22: ...e the debris from the bottom of the boiler Following completion of the above the boiler should be reassembled The integrity of the gaskets and insulation should be checked and replaced if necessary during re assembly Clean the burner bars and ensure that the holes slots are clear If necessary blow the slots and internals clear with compressed air or soft brush and vacuum On no account should the b...

Page 23: ...the reset button The use of a primary loop system is highly recommended to provide a constant boiler flow rate under all operating conditions Burner Lockout The boilers have an integral safety system to allow the safe and reliable operation of the burner Failure of the burner to operate correctly will cause the burner control box to lockout and the lockout button on the burner will illuminate to i...

Page 24: ...heat exchangers e Check the damper position f Check the rheostat position Stage 3 No ignition spark Pilot does not light Control box goes to lockout 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 no...

Page 25: ... valve and replace if necessary d Check control box Replace if necessary Stage 7 Pilot burner lights 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 load only 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 pressur...

Page 26: ...re switch 2nd stage 1st step indicator light 2nd step indicator light Boiler pump Blue wire neutral Flame ionisation probe Gas pressure switch Yellow green wire earth Live Pump switch ZSB MST TR1 TR VSC VSB ZT F1 TSB DGAI STB TF Burner reset Safety mode thermostat Flame failure indicator light Mains indicator light 1st stage control thermostat Overheat indicator light Burner test switch Fuse Burne...

Page 27: ...SECTION 6 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION AND MAINTENANCE MANUAL PAGE 24 DERWENT COMPACT PLUS CONDENSING ...

Page 28: ...tions 1 S136432A 6 Front top panel 8 sections 1 S136434A 7 Insulation board 4 sections 1 S136449H 7 Insulation board 6 sections 1 S136450H 7 Insulation board 8 sections 1 S136452H 8 Control panel assembly 4 sections 1 S136920H 8 Control panel assembly 6 sections 1 S136921H 8 Control panel assembly 8 sections 1 S136923H 9 Condensor casing assembly 6 sections 1 S137732A 9 Condensor casing assembly 4...

Page 29: ...tion 4 sections 1 S137751 15 Condensor casing side panel insulation 4 6 sections 2 S137737 15 Condensor casing side panel insulation 8 section 2 S137738 16 DGAI 73 MOD 10 3 30 TCL Z 1 S503755 17 Wire wound rheostat 25W 1000R 1 S503757 17a Rheostat locking system 1 S504016 18 Fan capacitor 4 6 sections only 1 S137757 19 Timed delay relay OMRON H3DS AL 1 S503756 20 Relay LY2F 220AC 1 S15815049 21 Rh...

Page 30: ...31166 S131168 6 Extension 526 L 50 1 S15922705 7 Bleed Tap 1 S17006472 8 Flow Pipe 4 Sections Flow Pipe 6 8 Sections 1 1 S17004722 S17004723 9 Elbow 1 6 8 Sections Elbow 1 4 Sections 1 1 S9125780 S15923012 10 Side Case Fixing Panel 6 Sections Side Case Fixing Panel 8 Sections Side Case Fixing Panel 4 Sections 1 1 1 S131317 S131326 S137922 11 Rear Panel Rear Panel Rear Panel 1 1 1 S137636 S137692 S...

Page 31: ... SN9170990 SN9171010 S15243610 30 O Ring Seals 1 SN9195220 31 Studs M10 x 120 1 S15245372 32 4 Entries Cable Locking System 1 S17076332 33 Strengthening Piece for Stability 4 Sections 1 S136478 34 Condensor Backflow Tube 6 8 Sections Condensor Backflow Tube 4 Sections 1 1 S137554 S137563 35 Boiler Backflow Tube 6 8 Sections Boiler Backflow Tube 4 Sections 1 1 S137555 S137562 36 Seal 30 x 22 x 2 GE...

Page 32: ...ections Air Pressure Switch 604 9040030W34 50 4 Sections 1 1 S504014 S504015 6 Air Pressure Switch 604 9140030W427 150 6 8 Sections Air Pressure Switch 604 9140030W427 400 6 8 Sections 1 1 S503792 S504013 7 Klixon US603UXTFSPH100 4ºc 1 S502259 8 Thermostat Wire 1 S137988 9 Axis 1 S137887 10 Damper 6 8 Sections Damper 4 Sections 1 1 S137721 S137891 11 Fan Seal 8 Sections Fan Seal 4 6 Sections 1 1 S...

Page 33: ...Side Flue Box Insulation 8 Sections 1 1 S137857 S137860 7 Right Hand Side Flue Box Insulation 6 Sections Right Hand Side Flue Box Insulation 8 Sections 1 1 S137856 S137859 8 Front Side Flue Box Insulation 6 Sections Front Side Flue Box Insulation 8 Sections 1 1 S137855 S137861 9 Back Side Flue Box Insulation 6 Sections Back Side Flue Box Insulation 8 Sections 1 1 S137858 S137862 4 Section Item No ...

Page 34: ...ION OPERATION AND MAINTENANCE MANUAL DERWENT COMPACT PLUS CONDENSING PAGE 31 General Item No Description Qty Part No 5 Ceramic Felt Seal 20 x 3 3m SN9205320 14 Flue Securing Plate 30 x 40 1 SN9180060 15 Wing Nut M8 x 20 1 SN9170180 16 Bag of Fixings 1 S504306 ...

Page 35: ...k Plate 8 Sections 1 1 1 S132465 S132806 S133742 4 Mounting Plate Insulation 8 Sections Mounting Plate Insulation 4 Sections Mounting Plate Insulation 6 Sections 1 1 1 S137030 S137032 S137034 4a Top Insulation 4 Sections Top Insulation 6 Sections Top Insulation 8 Sections 1 1 1 S135625 S135627 S135629 4b Side Insulation 2 S137100 5 Gas Manifold 6 Sections Gas Manifold 4 Sections Gas Manifold 8 Sec...

Page 36: ...n Glass 147 125 002 1 S137581 19 Pilot Tube 4 Sections Pilot Tube 6 Sections Pilot Tube 8 Sections 1 1 1 S137621 S137623 S137625 19A Burner Manifold Test Nipple 1 S17006201 20 Pilot Tap Tube 4 2 1 S136484 21 Pilot Tube Connection 4mm 1 S502835 23 Klixon US603UXTFSOH100 4ºC 1 S502259 23a TSB Wiring 1 S136818 24 Pilot Assembly 1 S137132 24a Pilot 1 S137131 25 Sparking Plug 1 S134257 26 Ionisation Pl...

Page 37: ...minal Support 1 S136979 10 Thermostat TXA4C 019 1 S17007004 11 Thermostat Lever 1 S17004738 12 12a Fuse Support Fuse TFS 5 x 20 6 3A 1 1 S15803999 S15803525 13 Bag of Lights 1 S501970 14 Bag of Switches 1 S503081 15 Thermostat TG400 Cap 2m 1 S17006955 16 Thermostat 68 5 x 14 5 0 120º 1 S134421 17 CB120 Module Front Panel 1 S137158 18 Relay LY2F 220AC 1 S15815049 19 Time Delay Relay OMRON H3DS AL 1...

Page 38: ... 5 5 Check gas available at burner 5 5 Check gas available at burner 5 6 Check oil available at burner 5 7 Check gas meter fitted sized adequately 5 8 Check that gas pipe has been purged 6 0 COMBUSTION Pilot Low High Unit 6 1 Inlet Gas Supply Pressure Boilers running mbar 6 2 Burner Pressure mmwg 6 3 Gas Rate m3 hr 6 4 Ionisation Probe UV Cell Current 6 5 c Air Shutter Position 6 6 O2 6 7 CO2 6 8 ...

Page 39: ...of Practice and Regulation see manufacturers instructions for full details Item 5 1 to 5 8 are related to the boiler instructions and as such these pre commissioning check should be carried out in the presence of the installer 10 0 NOTES COMMENTS BY COMMISSIONING ENGINEER FINDINGS YES NO Is The Installation Safe For Use If The Answer Is NO Has A Warning Label Been Raised Is Any Remedial Work Requi...

Page 40: ...w g 1 mm w g 0 0394 in w g 1 mm w g 9 8 Pa LENGTH 1 inch 25 4 mm 1 mm 0 03937 in 1m 1000mm 1 ft 0 3048 m 1 m 3 281 ft 1 yard 0 9144 m 1 m 1 094 yard 1 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 ...

Page 41: ...ice organisation covers the whole of the UK to look after your needs for all Potterton Commercial products We are also able to offer our services for other manufacturers products Our service department offers a wide range of specialised services including Boiler site assembly Burner commissioning for all fuels Boiler maintenance and maintenance contracts Breakdown and repair services Boiler disman...

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