Potterton Osprey CF 125 Installation & Service Instructions Manual Download Page 1 | Manualshive

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Potterton Osprey CF 125 Installation & Service Instructions Manual Download Page 1

Installation & Service Instructions

Osprey CF

125 – 220

About the Boiler

See inside cover for models covered by these instructions.
This Floor Standing Cast Iron Gas Boiler is available as Conventional Flue.
This boiler is for use with Natural Gas (G20) at 20mbar or Propane Gas (G31) at 37mbar and
for use in GB & IE.

About Safety

The Gas Safety (Installation and Use) Regulations 1994 (As Amended) & The Gas
Safety(Installation and Use) (Amendment) Regulations 1996.

‘‘ In your own interest, and that of safety, it is law that all gas appliances are installed by
competent persons, in accordance with the above regulations. Failure to install appliances
correctly could lead to prosecution.’’

Installation must be in accordance with the Installation & Service Instructions and the rules in
force.

Leave these instructions with the user for use on future calls.

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Summary of Contents for Osprey CF 125

Page 1: ...Safety The Gas Safety Installation and Use Regulations 1994 As Amended The Gas Safety Installation and Use Amendment Regulations 1996 In your own interest and that of safety it is law that all gas appliances are installed by competent persons in accordance with the above regulations Failure to install appliances correctly could lead to prosecution Installation must be in accordance with the Instal...

Page 2: ... Flue 16 3 Commissioning 17 3 1 Commission the Boiler 18 3 2 Final Adjustments 19 3 3 Instruct the User 19 3 4 Advise the User 19 4 Service Replacement of Parts 20 4 1 General Access 21 4 2 Control Panel 21 4 3 TTB Thermostat 22 4 4 Boiler Thermostat 22 4 5 Overheat Thermostat 22 4 6 Burner Assembly 22 4 7 Gas Valve 23 4 8 Pilot Interrupter 23 4 9 Pilot Assembly 23 4 10 Burner 23 4 11 Cleaning Hea...

Page 3: ... 75 1 75 1 75 1 75 Burner Pressure mbar 36 5 36 5 36 5 36 5 Permanent Pilot mm 1 Hole Ø 0 24 Injector Efficiency Gross 81 2 80 9 81 5 80 9 Injector Size mm 1 75 1 75 1 75 1 75 Water Content Litres 24 29 33 38 Appliance Weight kg 135 165 195 225 Nominal flow l min 45 6 56 0 68 8 84 0 for temp diff of 11K Pressure Loss mbar 9 7 18 7 27 5 55 9 for temp diff of 11K Maximum Working Head 30m 3 bar Minim...

Page 4: ...TECHNICAL DATA Page 4 Fig 2 ...

Page 5: ...k Act 1974 we are required to provide information on substances hazardous to health Small quantities of adhesives and sealants used in the product are cured and present no known hazards The following substances are also present Insulation and Seals Material Ceramic Fibre Alumino Silicone Fibre Description Boards Ropes Gaskets Known Hazards Some people can suffer reddening and itching of the skin F...

Page 6: ... carried out i e Earth Continuity Short Circuit Polarity and Resistance to Earth 1 3 Location of Boiler The boiler is not suitable for external installation The boiler must stand firm and level on a non combustible surface No special floor protection is needed but finishes which soften when warm e g linoleum and plastic floor tiles should be removed or may be protected by an insulating sheet at le...

Page 7: ...ted in the room containing the boiler special ventilation requirements must be implemented Refer to BS 5440 Part 2 and BS 6644 Any grille and or duct should be so sited and of a type not to become easily blocked or flooded and should offer low resistance to airflow If the boiler is installed in a compartment permanent air vents are required in the compartment one at high level and one at low level...

Page 8: ...e roof level and of a type approved by British Gas There should be at least 1000mm of vertical flue from the boiler flue socket Horizontal runs should be avoided however if a near horizontal flue run is unavoidable the total vertical height necessary should be calculated in accordance with BS 5440 1 and BS 6644 If an existing chimney is used ensure that it is thoroughly swept before lining or conn...

Page 9: ... of a fully pumped open system and a fully pumped sealed system are shown in Figs 6 7 The central heating should be designed as such that the minimum flow through the boiler is above 8 L min Sealed Systems Fully Pumped Installation The installation must comply with the requirements of BS 6798 1987 and BS 5449 1990 The British Gas publication British Gas Specification for Domestic Wet Central Heati...

Page 10: ...higher than the top point of the system and connected through a non return valve to the system on the return side of the hot water cylinder or the return side of all heat emitters or ii where access to a make up vessel would be difficult by using the mains top up method or a remote automatic pressurisation and make up unit as shown in Fig 8 Mains Connection There shall be no connection to the main...

Page 11: ...Installation Requirements Page 11 Fig 5 Fig 6 ...

Page 12: ...Installation Requirements Page 12 Fig 7 Fig 8 ...

Page 13: ...unpack the boiler 2 Do not discard any packaging until all the items are accounted for 3 Position the boiler to ensure the draft diverter is the required distance from the wall 4 Remove the top panel 2 screws 5 Remove the front door unhook and lift off 6 Fit the flue spigot supplied separately inside the case to the draft diverter Fig 9 ...

Page 14: ...in accordance with BS 6891 so that an adequate gas supply to the boiler is provided Do not turn the gas supply on at this stage 2 3 Connect the Water System 1 Connect system pipework to the boiler Arrange pipework to ensure correct venting of pipes and boiler The pipe diameter required will depend on boiler model and system design and may not be the same as boiler flow and return tappings Note Dra...

Page 15: ...ply cable pulls out of the cable clamp the live and neutral wires become taut before the earth wire 4 The pump wiring should be routed as the mains wiring through the cable clamps and connected to the terminal connections PL and PN Fig 12 5 Take up excess slack in the cables between the terminal block and the cable clamp then tighten the cable clamp screws Ensure sufficient slack is available to t...

Page 16: ...rmostat is to be fitted the connections should be made in the wiring external to the boiler 2 6 Install the flue 1 Install the natural draft flue according to BS 5440 and Fig 4 2 The boiler is fitted with a spillage device that will trip the boiler out under adverse conditions ...

Page 17: ...ent must only be carried out by a suitably qualified personnel Potterton Myson Ltd offer this service on a chargeable basis Important When purging and testing the gas supply for gas soundness open all windows and doors in the room Extinguish all naked lights cigarettes pipes etc ...

Page 18: ...open 9 Switch On the main electricity supply at the isolating switch or plug and socket 10 If a programmer is fitted set it to the On position and check that the room and cylinder thermostats where fitted are set to high temperatures 11 i Press control knob in lightly and turn Align off position with marker ii Press control knob in lightly and turn Align ignition position with marker iii Press con...

Page 19: ...Controls No further setting or checking is necessary as all boiler mounted controls are designed so that if a fault should occur they will fail safe External Controls Check that any other external controls connected in the system such as clocks or thermostats are correctly set and control the boiler as required Spillage Device Temporarily block the flue and check that the boiler shuts down within ...

Page 20: ...undness after completing any servicing of gas carrying components and carry out functional checks of controls IMPORTANT Ensure that the outer white case is correctly fitted Notes on Cleaning Boiler Components Heat Exchanger Place a sheet of paper under the heat exchanger after removing the burner assembly then using the brush Supplied with the boiler scrape the flueway fin surfaces in a downward m...

Page 21: ...be necessary to isolate the gas supply at the appliance isolating valve Important After removal or replacement of any gas carrying component a test for gas soundness must be made and functional check of the controls carried out Re assemble all parts in reverse order 1 Remove the front door by pulling forward then lifting up see Fig 15 2 Remove the top panel 2 screws at rear pull upwards and lift o...

Page 22: ...of the heat exchanger 3 Remove the user thermostat control knob 4 Unscrew the user thermostat note the wire connections each wire is numbered and remove the wires 5 Re assemble in reverse order 4 5 Overheat Thermostat Gain General Access See 4 1 1 Disconnect the wires from the thermostat 2 Unscrew the thermostat from the conducting Pocket 3 Re assemble in reverse order 4 6 Burner Assembly Gain Gen...

Page 23: ...e 4 1 1 Unscrew igniter 2 Unscrew thermocouple and pilot tube 3 Remove 2 screws and remove pilot assembly 4 Re assemble in reverse order 4 10 Burner Gain General Access See 4 1 1 Remove burner assembly See 4 6 2 Remove burner insulation 3 Unscrew 3 screws in burner plate and remove burner 4 Re assemble in reverse order 4 11 Cleaning Heat Exchanger Gain General Access See 4 1 1 Remove burner assemb...

Page 24: ...5 Wiring Diagrams Page 24 Fig 17 ...

Page 25: ...Wiring Diagrams Page 25 Fig 18 ...

Page 26: ...6 Fault Finding Page 26 ...

Page 27: ...Fault Finding Page 27 ...

Page 28: ...Fault Finding Page 28 Fig 19 ...

Page 29: ...7 Short List Of Spare Parts Page 29 ...

Page 30: ...A R E03 614 3 8000860 Injector A R E03 653 4 8000859 Injector Washer A R E03 652 5 8000909 Thermostat 1 E03 683 6 8000871 Limit Thermostat 1 E03 718 7 8000830 Pilot Burner 1 E03 639 8 8000832 Spark Electrode 1 E03 631 9 8000835 Pilot Injector 1 E03 643 10 8000838 Thermocouple 1 E03 642 11 8001171 TTB Spillage Thermostat Assembly 1 E03 685 Back Page ...

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