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Potterton Mersey Super, Installation And Service Instructions Manual

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Potterton Mersey Super Installation And Service Instructions Manual Download Page 25

 

Fig. 30 

g. Re-fit the water governor. 

h. Re-connect the burner supply pipe. 

i. Test for gas soundness as follows:- 

- Ensure the water service cock is in the OFF position, this will ensure that water CANNOT 

flow and open the automatic valve. 

- Turn ON the gas, purge and light the pilot, this will pressurise the burner supply pipe. 

- Test the burner supply pipe joints for gas soundness using leak detection fluid. 

j. Re-assemble remaining parts and ensure the water service cock is in the ON position. 

IMPORTANT: If the automatic valve and burner manifold complete is dismantled, it can 

only be tested for gas soundness under pressure AFTER blanking off all the injectors. 

 

Fig. 31 

Page 25 of 35

Mersey Super - Installation & Service Instructions

09/12/2009

file://P:\System\DATA\Dx\DS1\installation\2551\I24-2551\I24-2551.htm

Summary of Contents for Mersey Super

Page 1: ...ectly could lead to prosecution Installation must be in accordance with the Building Regulations Byelaws of the Water Undertaking and I E E Wiring Regulations It should be in accordance also with any relevant requirements of the Local Gas Region and Local Authority and the relevant recommendations of the following British Standard Codes of practice BS 6891 BS 5440 1 2 and BS 5546 LEAVE THESE INSTR...

Page 2: ...OFF DEVICE This appliance contains an Energy Cut Off Device that will shut down the gas supply to the appliance if the water within the heat exchanger exceeds the anticipated temperature limit after the hot water tap has been turned off See Page 21 VENTILATION Being a room sealed appliance the Mersey Super does not require an air vent in the room or space in which it is installed Where this applia...

Page 3: ...A D L MEDWAY MERSEY SEVERN 3 SEVERN 4 SEVERN 5 and TRENT Page 2 2 TECHNICAL SPECIFICATIONS Page 3 42 in 42 in In compartment which is ventilated to outside 137 cm 137 cm 21 in 21 in Finish White stoved paint with contrasting chassis Weight Packed 21 0 kg 46 2 lb Weight without Water 17 8 kg 39 2 lb Weight with Water 18 6 kg 41 0 lb Water Capacity 0 75 litre 0 17 gall Input 30 3 kW 103 000 Btu h Ma...

Page 4: ... be installed in a cupboard the ventilation openings in the cupboard must NOT be blocked DO NOT USE THE CUPBOARD FOR STORAGE Pilot injector 0 27mm marking A Nominal burner pressure maximum input 12 5 mbar 5 in w g Connections Gas 15mm Copper Tail 15mm Compression Water Balanced flues telescopic Wall thickness available 100mm 150mm 4in 6in Part No 31 1 0321 150mm 230mm 6in 9in Part No 31 1 0322 230...

Page 5: ...ixing nuts and washers Make good any damage to the brickwork or plaster around the terminal Cut off the existing pipework at a convenient point below the appliance 2 If installing a new flue terminal guidance is given on the template sheet supplied with the terminal pack Page 5 of 35 Mersey Super Installation Service Instructions 09 12 2009 file P System DATA Dx DS1 installation 2551 I24 2551 I24 ...

Page 6: ...packaging 5 Slide off the bottom cover then remove the three screws securing the outer case and carefully lift it off Fig 4 6 Use the self adhesive discs supplied to cover the unwanted fixing holes in the back of the new appliance as shown Page 4 INSTALLATION Page 5 7 Fit the flue terminal sealing strip packed separately in the carton into the recess around the flue aperture in the back of the app...

Page 7: ...2 Depending on whether the main supply pipe is to be routed vertically or horizontally to the appliance connect the gas service cock stamped G either directly to the gas inlet tail or within the supply pipe NOTE The service cock should be as close to the appliance as possible and the ON OFF screw in an accessible position 3 Ensure that the gas supply is turned OFF at the mains 4 Connect to the gas...

Page 8: ...Fig 6 Page 5 INSTALLATION Page 6 Page 8 of 35 Mersey Super Installation Service Instructions 09 12 2009 file P System DATA Dx DS1 installation 2551 I24 2551 I24 2551 htm ...

Page 9: ...cessible position 3 Ensure that the mains water supply is turned OFF IMPORTANT When routing the supply pipe to the appliance ensure that it can be lowered by approx 25mm to allow for disconnection when servicing 4 Connect the hot water supply pipes to the water outlet 15mm compression 5 Turn ON the mains water supply turn ON the water service cock and open all the hot water outlets to allow water ...

Page 10: ...r case of this appliance is not merely a cosmetic device It is a functioning component in the air supply to the burner and MUST BE replaced with great care NOW before any attempt is made to light the burners TO ALLOW THE MAIN BURNER TO IGNITE WITHOUT THE CASE IN POSITION IS A HAZARD 1 Refit the outer case ensuring it is correctly seated then secure 3 screws Fig 9 Page 10 of 35 Mersey Super Install...

Page 11: ...n for a further 10 seconds after the pilot is lit then release If the pilot goes out repeat the lighting operation keeping the ON button depressed a little longer 7 Test for gas soundness using a suitable leak detection fluid on all external gas joints 8 Open a hot water outlet and the burner will ignite Allow the water to run for a few minutes then check the burner pressure it should be 12 5 mbar...

Page 12: ...e OFF button on the appliance Remove the pressure gauge and replace the screw and sealing ring 10 Relight the pilot Turn ON a hot water outlet and check for gas soundness at the pressure test point 11 Turn OFF the hot water outlet Slide the bottom cover onto the appliance Page 12 of 35 Mersey Super Installation Service Instructions 09 12 2009 file P System DATA Dx DS1 installation 2551 I24 2551 I2...

Page 13: ...particular installation conditions and usage but in general once per year should be adequate IMPORTANT It is the law that any service work must be carried out by competent persons such as British Gas or other c o r g i registered personnel NOTE In hard water areas scale may build up on the push rod seals and on the underside of the diaphragm housing They may require regular descaling and regreasin...

Page 14: ...e piezo unit flame safety device and thermocouple clean or replace if necessary 2 Remove the burner assembly and clean using a soft brush or vacuum cleaner 3 Check the pilot injector and clean or replace if necessary Also clean the lint filter 4 Remove the water governor assembly complete with push rod Replace the seals if necessary Descale and regrease the push rod washers and diaphragm housing u...

Page 15: ...CING TURN ON ALL HOT TAPS TO PURGE AIR FROM THE WATER SYSTEM TURN THEM OFF IN SEQUENCE STARTING WITH THE TAP AT THE LOWEST LEVEL 2 WHEN REPLACING ANY PARTS RE ASSEMBLE IN REVERSE ORDER UNLESS OTHERWISE STATED This chart shows the steps to be taken in order access a specific part or perform a particular function Use this chart in conjunction with the detailed procedures on the following pages Page ...

Page 16: ... OF PARTS Page 11 6 1 PIEZO UNIT It will NOT be necessary to remove the outer case Page 16 of 35 Mersey Super Installation Service Instructions 09 12 2009 file P System DATA Dx DS1 installation 2551 I24 2551 I24 2551 htm ...

Page 17: ...ff the button and unscrew anti clockwise the piezo from its housing Fig 17 6 2 GENERAL ACCESS MAIN BURNER a Turn OFF the gas and water supplies at the service cocks b Slide out the bottom cover c Remove the 3 fixing screws and pull off the outer case Fig 18 Page 17 of 35 Mersey Super Installation Service Instructions 09 12 2009 file P System DATA Dx DS1 installation 2551 I24 2551 I24 2551 htm ...

Page 18: ...assembly can be dismantled and the burner bars replaced individually On re assembly ensure that the burner inlets locate in the 14 holes NOTE On re assembly of the burner assembly take care not to snag the pilot assembly Ensure the front face of the assembly has located on the two studs on the heating unit Fig 19 Page 11 REPLACEMENT OF PARTS Page 12 Page 18 of 35 Mersey Super Installation Service ...

Page 19: ...f the appliance The thermocouple will be vertical and nearest the burner manifold Fig 21 6 4 PILOT INJECTOR a Gain general access see 6 2 b Lift up the lint filter disconnect the union nut and carefully lift up the pilot tube taking care not to lose the pilot injector c On re assembly ensure the pilot injector is correctly seated taper side down and that the lint filter is correctly assembled and ...

Page 20: ...reverse order Page 12 REPLACEMENT OF PARTS Page 13 h Test for gas soundness as follows Ensure the water service cock is in the OFF position This will ensure water cannot flow and open the automatic valve Turn ON the gas purge and light the pilot this will pressurise the burner supply pipe Test the gas supply to flame safety device and burner supply pipe above the flame safety device for gas soundn...

Page 21: ...llow the water to drain Fig 24 6 7 WATER GOVERNOR a Gain general access see 6 2 b Drain the appliance see 6 6 c Release the inlet water connection and lower the pipework to clear the inlet d Release the union nut and clamping plate then remove the feed pipe Replace the O ring Page 21 of 35 Mersey Super Installation Service Instructions 09 12 2009 file P System DATA Dx DS1 installation 2551 I24 255...

Page 22: ...or to the chassis base g Carefully withdraw the governor complete with pressure relief valve TAKE CARE NOT TO BEND THE PUSH ROD IF THE ROD IS BENT A NEW ONE MUST BE FITTED h Remove the push rod i Remove 6 screws and separate the two halves of the water governor Page 22 of 35 Mersey Super Installation Service Instructions 09 12 2009 file P System DATA Dx DS1 installation 2551 I24 2551 I24 2551 htm ...

Page 23: ...ired On re assembly tighten the fixing nut finger tight plus a turn only m Check and if necessary replace the transfer port O ring n Ensure the diaphragm assembly is correctly seated then re assemble the two halves of the governor Insert the 6 screws and secure finger tight Fully tighten all 6 screws in the order shown o Clean regrease and re fit the push rod or replace with a new one Fig 28 Page ...

Page 24: ... the flame safety device Do not lose the O ring e Release the retaining plate 2 screws and remove the burner supply pipe Do not lose the O ring f Prise the manifold location brackets apart and carefully lift out the complete assembly IMPORTANT The automatic valve and burner manifold are only available as a combined assembly Retain all screws and O rings from the old assembly or renew NOTE On re as...

Page 25: ...burner supply pipe Test the burner supply pipe joints for gas soundness using leak detection fluid j Re assemble remaining parts and ensure the water service cock is in the ON position IMPORTANT If the automatic valve and burner manifold complete is dismantled it can only be tested for gas soundness under pressure AFTER blanking off all the injectors Fig 31 Page 25 of 35 Mersey Super Installation ...

Page 26: ...ing unit located top front left d Disconnect the 2 unions e Remove 4 screws securing the unit to the chassis f Carefully pull the unit from the top and lift DO NOT lose the 0 rings and washers g Remove the primary flue secured by 4 screws 2 front 2 rear Page 26 of 35 Mersey Super Installation Service Instructions 09 12 2009 file P System DATA Dx DS1 installation 2551 I24 2551 I24 2551 htm ...

Page 27: ...cess see 6 2 b Drain the appliance see 6 6 c Remove the heating unit see 6 10 d Invert the heating unit on a suitable bench or table e Using rubber tube and acid resisting tanks assemble as shown in fig 33 f Fill the upper container with a proprietary brand of descalent or a solution of 10 parts water to 1 part hydrochloric acid The water should preferably be hot then add ACID to WATER not water t...

Page 28: ...bs Bend back the tabs and remove the glass and seal Secure the new glass and seal to the outer case by bending over the 2 spare straight tabs Fig 34 6 13 ENERGY CUT OFF DEVICE a Gain general access see 6 2 b Disconnect the energy cut off leads from the interrupter located on the underside of the chassis c Remove the 2 screws securing the energy cut off device to the heating unit located top front ...

Page 29: ...or refer to the Instructions for Use 4 Electrode lead not connected to the rear of the spark igniter 4 Re connect the electrode lead 5 Incorrect spark gap 5 The gap between the electrode tip and the pilot hood should be 3 4mm 6 Current tracking to earth 6 Check the electrode lead is routed clear of all metal parts 7 Pilot injector blocked 7 Clear injector by blowing through or replace with pilot i...

Page 30: ...rmocouple worn out or damaged 3 Replace the thermocouple Part No 10 17461 4 Faulty magnet unit in the flame safety device 4 Replace flame safety device Part No 10 13477 5 Energy cut off device connections loose 5 Tighten connections 6 Energy cut off device may be faulty 6 Check for continuity and replace if necessary Part No 10 17792 SYMPTON POSSIBLE CAUSE SOLUTION PILOT LIT BUT MAIN BURNER WILL N...

Page 31: ...ocked water filter 1 Clean the debris from the filter 2 Heat exchanger blocked with lime 2 Descale or replace Part No 10 17558 3 Loss of service water main pressure 3 Contact your Local Water Authority HIGH WATER FLOW RATE See LOW WATER TEMPERATURE HIGH WATER TEMPERATURE 1 Automatic gas valve push rod sticking Water rate will be normal 1 Dismantle clean and regrease using Dow Corning 111 silicone ...

Page 32: ...ins to discolour and buckle 1 Descale or replace Part No 10 17558 2 Noisy ignition could be caused byincorrect setting of the slow ignition screw 2 See Fig 16 for the position of the screw Turning the screw clockwise delays the ignition anti clockwise advances the ignition The screw should be set 2 full turns out anticlockwise from the fully in position When correct the burner ignition should be s...

Page 33: ...hat STEAM will come out of the hot water tap when turned on IMPORTANT NOTE To ensure continued safe operation we recommend that if the pressure relief valve has operated it should be replaced immediately page 21 8 SHORT SPARE PARTS LIST Page 22 SYMPTOM POSSIBLE CAUSE SOLUTION SMELL OF COMBUSTION PRODUCTS 1 Faulty case or terminal seal 1 Check that the outer case seal Part No 10 17501 and terminal ...

Page 34: ...Page 22 Page 34 of 35 Mersey Super Installation Service Instructions 09 12 2009 file P System DATA Dx DS1 installation 2551 I24 2551 I24 2551 htm ...

Page 35: ... 50 285 929 Thermocouple Connection Special 1 10 17790 49 397 688 Interrupter Insert 1 10 13846 52 285 931 Electrode Assembly 1 10 17493 55 285 679 Pilot Injector Special 1 19 12690 41 393 492 Piezo Unit RV 1174 1 10 11935 56 285934 Igniter IGN Button 1 10 17507 57 285 935 Starter ON Button Assembly 1 10 17540 58 285 936 Stop 0FF Button Assembly 1 10 17541 80 285 955 Diaphragm Assembly 1 10 17572 ...

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