Potterton Statesman Flowsure L Installation & Service Instructions Manual Download

Page: 38 / 52

Part No. 5106463

Servicing & Maintenance

ST00254A

Remove The Two

Retaining Screws

And Split The

Controls Box

Assembly Apart

Remove

Front Cover

Disconnect

Clock

(If Fitted)

Lift Off The

Facia &

Disconnect

The Indicator

Lights Plug

Remove

Facia

Securing

Screws

Remove The
Temperature

Control Knob

Remove

Sensor

From

Pocket

The Side

Casing

Caution

Avoid Over

Bending

Control

Box

Assembly

Replacing

Thermostats

(Front Access)

Remove The

Retaining Nut

& Boiler Stat
(If Required)

Rear

View

Control

Box

Assembly

Remove Retaining

Nut & Limit Stat

(If Required)

Fig. 27

Replacement of Thermostats
(Statesman System)

1. Remove the front cover.
2. Pull off the temperature control knob.
3. If a clock is fitted un-clip from the facia and

disconnect the plug at the back.

4. Remove the facia retaining screws at the base

of the facia.

5. Lift off the facia and disconnect the indicator

lights plug.

6. Remove the retaining screws and split the

controls box assembly apart.

Note which way the electrical connectors fit before
removing any of the thermostats.

Re-assemble in reverse order unless stated
otherwise.

Limit Thermostat

1. Disconnect the electrical connections.
2. Remove the clip and withdraw the temperature

gauge bulb and limit thermostat sensor from
its pocket.

3. Remove the locknut securing the thermostat

to the controls assembly. On re-assembly
insert the thermostat sensor before the
temperature gauge bulb.

Boiler Control Thermostat

1. Disconnect the electrical connections.
2. Remove the clip and withdraw the sensor from

its pocket.

3. Remove the locknut securing the thermostat

spindle to the controls assembly.

Summary of Contents for Statesman Flowsure L

Page 1: ...flue This boiler is for use with Kerosine and for use in GB IE This boiler can be converted for use with Gas Oil AboutSafety 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 Statesman System L Flowsure L Flowsure L Installation Service Instructions ...

Page 2: ...rmostat 38 Boiler Control Thermostat 38 Thermostats Statesman Flowsure Flowsure 39 Boiler Control Thermostat 39 Limit Thermostat 39 Pump Overrun Thermostat 39 Tank Limit Thermostat 39 DHW OverheatThermostat 39 Heatstore Thermostat 39 Automatic Air Vent 39 Pressure Relief Valve 40 Circulating Pump 40 Expansion Vessel 40 Pressure Temperature Gauge 40 Diverter Valve 40 Flow Switch 40 Domestic Service...

Page 3: ...a doctor DO NOT INDUCE VOMITING NEVER APPLY heat to a fuel tank pipework or container AVOID INHALING fuel vapour it can make you light headed and seriously impair your judgement ALWAYS STORE fuels in a properly constructed and labelled tank If there is a Fuel Spillage IMMEDIATELY STOP SWITCH OFF all electrical and other ignition risks REMOVE all contaminated clothing to safeguard yourself against ...

Page 4: ...low good hygiene practices wash hands before touching eyes consuming food drinking or using the toilet First Aid Medical attention must be sought following eye contact or prolonged reddening of the skin Flue Gas Sampling Point To aid commissioning a flue gas sampling point is built into the heat exchanger front access door If this door is removed make sure that when re fitted the sampling point is...

Page 5: ...k on Flowsure to the heat exchanger whenever there is a flow of domestic water through a hot water tap The domestic water thereby extracts the heat from the plate heat exchanger giving mains pressure domestic hot water The domestic hot water temperature can be increased by reducing the water flow rate at the tap Flowsure or adjusting the hot water mixing valve to a higher setting Flowsure Pump ove...

Page 6: ...l Connection Boiler Drain Valve Burner Air Inlet Pipe Burner Lockout Reset Button Burner Oil Feed Pipe Knock out Blanks For Cables And Fuel Pipes Thermostat Pocket Programmer Optional Expansion Vessel Cradle Pressure and Temperature Gauge Expansion Vessel Connection Pipe Combustion Chamber Viewing Window Combustion Chamber Access Panel Flow 22mm Return 1 B S P Left Right hand Statesman System Conv...

Page 7: ...ostat Pocket Plate Heat Exchanger D H W Limit Pocket Expansion Vessel Expansion Vessel Valve Expansion Vessel Connection Pipe Expansion Vessel Support Bracket 3 Way Diverter Valve C Heating Return 1 B S P C Heating Return 1 B S P Boiler limit Stat Temp Gauge Bulb Pocket Expansion Vessel Connection Boiler Drain Valve Double Check Valve System Fill Flexible Hose DO NOT use as a permanent fitting Sys...

Page 8: ...ved For Clarity Conventional Flue Boiler Limit Stat Temp Gauge Bulb Pocket Tank Limit Stat Pocket Plate Heat Exchanger Plate Heat Exchanger Expansion Vessel Connection Valve Expansion Vessel Connection Pipe Expansion Vessel Support Bracket Expansion Vessel Expansion Vessel Valve 3 Way Diverter Valve Double Check Valve C Heating Return 1 B S P System Fill Flexible Hose DO NOT use as a permanent fit...

Page 9: ...minal Block Overheat Burner Lockout Mains On N E L Burner Socket Main Socket Chassis Earth Boiler Terminal Socket 6 way Boiler Terminal Plug 6 way Limit Stat Boiler Stat L2 L1 E N 1 1 2 2 Main Supply Connection b g y g y br br br r b b g y bl gy br br br r bl bl b br b br b b b br N E L Live Main Supply Connection L L E E N N S L S L Neutral Earth br g y b L E Boiler Wiring Diagram Statesman Syste...

Page 10: ...ack b g y br r b b g y bl br br N E L Live Main Supply Connection L N S L S L Neutral Earth 11 1 31 11 A2 10 A1 2 14 3 34 9 12 4 32 8 22 5 24 7 21 6 Flow Switch Diverter Valve Pump Tray Assembly L L 1 1 E E N N L L S L S L L L L N E Relay br br v o b g y gy gy y o r v o br bl bl o r br br br br br b b b bl bl b b p b g y b b br p gy w g y g y w gy bl br br r bl y b b LINK to be replaced with room ...

Page 11: ...L S L Neutral Earth 11 1 31 11 A2 10 A1 2 14 3 34 9 12 4 32 8 22 5 24 7 21 6 Flow Switch Tank Thermostat Diverter Valve Pump Tray Assembly L L 1 1 E E N N L L S L S L L L L N E Relay 1 2 br br v v o g y gy o r v o br bl bl o r br br br br br b b b bl bl b b p b g y b b br p w g y g y w gy bl br br r bl gy gy 0 47 UF Capacitor LINK to be replaced with room thermostat L N CH ON HW ON 1 1 1b 1a 1a o ...

Page 12: ...aximum Surface Temperatures of Adjusting Control Safety Devices Less Than 30ºC Above Room Temperature Electrical Supply 230V 1 Phase 50Hz Fuse 5A DHW Limit Thermostat Setting 85ºC 185 F DHW Store Thermostat Setting 73ºC 163F DHW Store Limit Thermostat Setting 88ºC 190ºF Pump Overrun Thermostat Setting 80ºC 176ºF 88ºC 190ºF Flow Restrictor 13 l m Brown 17 5 l m Green Maximum DHW Flow Rate 13 1 5 l ...

Page 13: ...590 565 100 125 97 59 1 B S P 22mm 15mm 15mm 15mm 170 60 0 13 2 610 12 6 25 If mounted under a worktop the top needs to be removed Table 2 Boiler Dimension Clearances SEDBUK Declaration for Statesman Gas Oil Mid Range Model Seasonal Efficiency SEDBUK System 85 5 Flowsure 82 7 Flowsure 82 9 This value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings Th...

Page 14: ... Roof Kit 3 Kit 4 Kits 9 or 10 770mm Floor Level Kits 1 2 Kits 7 8 Kits 5 6 if required Kits 5 6 if required Kit 3 2 150m Min 4 550m Max 20mm Flue Outlet Flue Outlet Flue Outlet C D D A Flue Outlet B Boiler Dimensions D Knock out Blanks For Cables And Fuel Pipes G J H 6mm or 25mm Min D Low Level Riser Flue Kits 12 5 6 7 8 For Flue Lengths see tables 990mm Floor Level Kits 7 8 Kit 12 Kits 5 6 if re...

Page 15: ...e requirements of the Building Regulations which are statutory instruments and must be complied with Those for England and Wales are made by the Department of the Environment in London The Building Standards Scotland Regulations are made by the Scottish Office Part F of the Technical Standards to the Regulations covers heat producing appliances and fuel storage The Building Regulations Northern Ir...

Page 16: ...s an alternative to a conventional structural chimney for both new and existing buildings A further alternative may be a suitable form of insulated flue pipe normally positioned on a wall outside a building Capacity The chimney or flue must have a cross sectional area throughout its whole length that is at least the area of the flue outlet of the boiler and must be sealed at the boiler with fire c...

Page 17: ...prevent overheating of the appliance and any equipment in and near the appliance c For the satisfactory operation of any draught break or stabilizer which may be fitted Air for Combustion This requirement will be satisfied if the room or space in which the appliance is installed has an opening or duct which is designed to allow the passage of air at all times equivalent in total free area to 550 m...

Page 18: ...mitting devices the warm air from the terminal will encourage the accumulation of dirt which will at some time require removal with a detergent based cleaning fluid Clearances are shown on the next page Fig 12 Extract Fans If the room in which the appliance is located also has an extract fan the performance of the appliance must be unaffected when the fan is running with all doors and windows clos...

Page 19: ...minal Assembly 300 min Top View Pressure Jet Appliance FLU0004A A Directly below an opening air brick opening window etc B Horizontally to an opening air brick opening window etc C Below a plastic painted gutter drainage pipe or eaves with protection D Below a balcony or a plastic painted gutter drainage pipe or eaves E From vertical sanitary pipework F From an internal or external corner G Above ...

Page 20: ... Protection It is considered unlikely that a fire will originate from the stored oil and it is the purpose of these recommendations to ensure that a fire which may originate from a building or other external source is not transmitted to the tank contents Adequate safety may be achieved in a number of ways for example a Protecting the tank by a physical barrier or isolating the tank by sufficient s...

Page 21: ...is at least equal to the cross sectional area of the fill pipe The vent should normally rise no higher than 600 mm above the top of the tank If the vent pipe rises more than 600 mm above the tank a pressure relief outlet must be provided in the vent at the 600 mm level This is normally a horizontal branch off the vent with a flap at its end This is hinged at the top and fitted so that it is normal...

Page 22: ...e located just outside the building at the point where the oil supply line enters It must be activated by a remote sensor located over the burner but in a position clear of any direct radiation or excessive heat Weight operated valves connected to a sensor by wires and pulleys have been used for this purpose It is preferable however to use a valve with a capillary connection between its sensor and...

Page 23: ... valve operates at 3 bar 45 lb in Install a pressure relief valve discharge pipe not less than 15 mm diameter and connect to the pressure relief outlet connection using a 15 mm compression fitting The pipe run should be as short as possible run continuously downwards and discharge to the outside of the building where possible over a drain The discharge point must be such that it will not be hazard...

Page 24: ...he safety valve setting i e 3 65 bar Statesman Flowsure and Flowsure The final 600 mm of the mains cold water connection to the boiler should be made in copper tubing to BS 2871 Pt 1 which is recommended for water carrying pipework and must be used for pipework carrying potable water All capillary joints in the D H W pipework must be joined with a lead free solder The boiler is suitable for mains ...

Page 25: ...0203A 150mm Pump Twin Pipe Supply System B Max Oil Level 4 metres Above Burner Fire Valve Shut Off Valve Filter Fire Valve Sensor Pump A Single Pipe Supply System Max Head 4m Oil Tank Below or Level with Burner Fire Valve De Aeration Device Isolating Valve Isolating Valve Oil Supply Pipe Filter Fire Valve Sensor Pump Fig 17 Fig 16 Pre Installation Requirements ...

Page 26: ... 6 Casing Kits 5 and or 6 Extension Dress Plate Outer Wall Dress Plate Inner Wall Max Min The terminal can be extended between these markers Wall Width Low Level Rear Kit Numbers 100 275 225 600 600 900 900 1200 1200 1550 1550 1850 1 2 2 6 2 6 6 2 5 2 5 6 Low Level Horizontal Kits 1 2With Extensions 126 12 Min 880 770 Casing Kits 1 2 Flue Dress Plate Outer Wall Dress Plate Inner Wall Floor Level A...

Page 27: ...k the boiler b Select the desired oil feed position and remove the appropriate knockout in the base using a suitable drift c Position boiler d Lift off top casing panel e Carefully remove knockout panel in top casing panel using gentle manipulation f Seal flue pipe to boiler with fire cement g Re fit top casing panel Connecting the Electricity Supply Electrical Connections All electrical wiring mu...

Page 28: ...control panel This door is designed to come off if any undue pressure is exerted on it when open but can easily be snapped back into place It may however become detached if the appliance has been handled roughly during transit If you find the door is missing when opening the carton check to see if it is amongst the packaging Fuel Pipes Refer to Section 2 Figs 14 16 17 plus Tables 4 and 5 Before co...

Page 29: ...Part No 5106463 29 Fig 21 Installation Commissioning ...

Page 30: ...Orange p Pink g y Green Yellow L S L S L g y p br b L N N HW ON CH ON b p o w br y 1 2 3 Room Stat Or Programmable Stat Detail With Room Stat Frost Stat Remove Link Boiler Terminal Socket Press Temp Terminal Plug Frost Stat gy Clock Electro mech Wiring Diagram External Controls Statesman Flowsure Flowsure Flowsure Only ...

Page 31: ...10 below the burner The difference in levels between the pump and the suction and the return lines in the tank controls the maximum length of pipe including horizontal and vertical runs It is necessary to enable the pump to raise the oil out of the tank Problems can be encountered with air collecting on shut down if the fuel pump is situated at the highest point in the system Water Connections Sta...

Page 32: ...32 Part No 5106463 Installation Commissioning Fig 23 ...

Page 33: ... 20 seconds If the flame is not established during this time the burner lock out neon will light wait about a minute before pressing the reset button to re commence the lighting sequence Continuous failure to light is almost certainly due to air remaining in the fuel supply 9 Start and stop the burner two or three times until the flame cuts off sharply this indicates any remaining air has been dis...

Page 34: ...ecessary water connections those connections not utilised should be plugged 5 Check that the central heating system has been fully flushed out at installation using a flushing agent If not add a suitable flushing agent to the system and fill the system Then drain the system while hot and immediately refill adding a suitable proprietary corrosion inhibitor such as Fernox The following procedures sh...

Page 35: ... Replace if Necessary Remove The Baffle Plate Examine For Damage Replace If Necessary Lift Out The Plate With This Hole Front Access Door Clean Combustion Head LD2SH Model Shown Clean Ignition Electrodes Replace Nozzle With One Of Identical Type Disconnect Burner Air Supply Pipe Disconnect Flange Disconnect Burner Plug Disconnect Suction Line ST00261A Remove Burner Expansion Vessel removed for cla...

Page 36: ...Instructions Note Check all seals and replace if damaged Remove access door on front of boiler remove retarders and baffle plate noting their positions Brush off all deposits if they show signs of damage replace Examine interior of boiler and if necessary clean Remove any loose debris from the combustion chamber Check the condition of the refractory base and repair any minor cracks with fire cemen...

Page 37: ...p as necessary using the filling system provided Filling must be carried out with the system cold so that the pressure can be brought up to the original cold fill reading indicated by the red pointer A careful watch should be kept on the pressure gauge during filling and the mains pressure valve opened slowly Topping up may by arrangement be a part of the annual service contract Replacement of Par...

Page 38: ...d un clip from the facia and disconnect the plug at the back 4 Remove the facia retaining screws at the base of the facia 5 Lift off the facia and disconnect the indicator lights plug 6 Remove the retaining screws and split the controls box assembly apart Note which way the electrical connectors fit before removing any of the thermostats Re assemble in reverse order unless stated otherwise LimitTh...

Page 39: ...its pocket 3 Remove the locknut securing the thermostat to the controls assembly On re assembly insert the thermostat sensor before the temperature gauge bulb Pump OverrunThermostat 1 Disconnect the electrical connections 2 Unscrew the two screws securing the thermostat to the controls assembly 3 Remove the clip and withdraw the sensor from its pocket Tank LimitThermostat Flowsure 1 Disconnect the...

Page 40: ... Un clip the temperature pressure gauge from its bracket remove gauge carefully withdrawing sensor and bulb capillary tubes through bracket assembly 6 Fit a replacement gauge in the reverse order 7 Open the valves and fill the system as described in Section 2 Pre Installation Requirements DiverterValve Flowsure Flowsure 1 Drain the boiler using the boiler drain point provided 2 Turn off the isolat...

Page 41: ...Close the mains water isolating valve to the boiler drain the residual water from the hot water pipework Flowsure 1 Remove the flow switch refer to paragraph flow switch replacement in this section 2 Undo nut on cold inlet pipe feed to PHE remove pipe 3 Undo nut on hot water outlet pipe from the PHE remove pipe 4 Slacken the two screws retaining the DHW flow pipe to the diverter valve Undo the nut...

Page 42: ...ermostat Boiler Thermostat Neon Connector 6 way Burner Socket Mains Socket Diverter Valve Manual Air Vents Limit Thermostat and Temperature Gauge Bulb Pocket Flow Switch Type 1 Plate Heat Exchanger Domestic Service Cock Inside Electrical Connector 6 way Rear Electrical Connector 6 way Plate Heat Exchanger Controls Assembly Lid Automatic Air Vent Pressure Sensor Pump Overrun Pocket Pressure Relief ...

Page 43: ...hermostat and Temperature Gauge Bulb Pocket Flow Switch Type 1 Flow Switch Type 2 Plate Heat Exchanger Inside Electrical Connector 6 way Rear Electrical Connector 6 way Automatic Air Vent Pressure Sensor Pump Overrun Pocket Flue Spigot Pressure Relief Valve Controls Assembly Controls Assembly Lid ST00256A Mixing Valve Primary Water Heatstore Domestic Service Cock Certain Items Removed For Clarity ...

Page 44: ...efer to wiring diagram Section 1 12 Burner motor seized Remove and check ease of rotation SYMPTOM CHECK FOR ACTION Burner Starts No Flame Established No Oil To Burner 1 Oil in the tank Re Fill 2 All valves open from tank to burner Open valves 3 Fire valve correctly set Set as per manufactures instructions 4 Filter blocked Clean and replace elements 5 Air lock in fuel lines Bleed burner 6 Nozzle bl...

Page 45: ... Replace pump assembly SYMPTOM CHECK FOR ACTION Burner Starts Flame Established But Goes To Lock Out After 15 Seconds 1 Intermittent oil supply Check for dirt in filters or oil in fuel lines 2 If two pipe system that pipework Refer to Table 5 Page 23 is correct 3 Combustion head settings correct Refer to Burner Instructions 4 Photocell not fitted correctly Replace correctly 5 Photocell circuit fau...

Page 46: ...in and refill tank correctly 2 Correct nozzle fitted Refer to Burner Instructions and fit correct nozzle 3 Correct oil pressure Refer to Burner Instructions and set correct pressure 4 Correct air settings Do combustion checks and re set 5 Air in fuel lines Bleed air from lines 6 Adequate access for combustion air Refer to Section 2 7 Adequate ventilation Refer to Section 2 8 One sided flame Remove...

Page 47: ... temperature necessary replace too high 3 Lack of flow through boiler If possible try circulating pump on higher setting Statesman only 4 Condensation from Chimney Could take place in cold weather due to high efficiency of boiler Check system complies with Standard 5 Noisy Motor Look for signs of oil leaking from pump motor and coupling 6 Pump pressure oscillating Air in oil Dirt in pump regulatin...

Page 48: ...20 Pressure Safety Valve E F G 404S601 21 Circulating Pump E F G 405 0317 22 Pressure Temperature Gauge E F G 26009159 23 Diverter Valve F G 26009160 24 Double Check Valve F G 26009144 25 Flow Switch F G 26009166 26 Switch 2 Position F G 26009090 27 Pump Overrun Thermostat F 404507 Pump Overrun Thermostat G 26009156 28 Plate Heat Exchanger F 26009107 29 Plate Heat Exchanger G 26009146 30 DHW Limit...

Page 49: ...wsure Flowsure 10 11 11 8 2 43 9 Not Spared 14 12 13 15 1 3 4 16 25 25A 17 27 30 32 40 34 31 18 33 41 42 19 35 21 28 29 23 22 24 26 39 37 38 36 20 24 1 2 3 4 5 6 7 8 1 1121 3 1 4 1 5 1 6 1 7 18 1 9 2 0 2 1 22 23 1 0 9 7a 7 7a Spare Parts Fig 33 ...

Page 50: ...ontal Low Level Telescopic Short Wall 100 275mm Inner Wall Fasteners Pack 4 wall plugs 4 wood screws KIT 1 Gasket Inner Seal Instructions Outer Seal Dress Plate Horizontal Low Level Telescopic 225 600mm Inner Wall Dress Plate Outer Wall Dress Plate Outer Wall Fasteners Pack 4 wall plugs 4 wood screws KIT 2 ST00139C ...

Page 51: ... Short Wall 100 275mm Kit 7 Horizontal and Vertical Flue Extension 950mm Horizontal and Vertical Flue Extension 300mm Kit 5 Kit 6 Horizontal High Level Telescopic 225 525mm Kit 8 Flashing Flat Roof Kit 9 Low Level Riser Kit 12 Vertical High Level Riser Telescopic Kit 3 Gasket Instructions Fasteners Pack 4 Wall Plugs 4 Wood Screws Inner Seals 1 off Dress Plate Outer Wall Dress Plate Inner Wall Dres...

Page 52: ...ductswhichmayaffecttheaccuracyoftheinformation contained in this leaflet All goods are sold subject to our standard ConditionsofSalewhichareavailableonrequest To aid continuous improvement and staff training calls to this line may be monitored or recorded General Enquiries Tel 08706 060 780 Technical Tel 08706 049 049 Service Tel 08706 096 096 Fax 01926 410 006 Literature Request Tel 08706 060 623...

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