Potterton Osprey 2 CFL 125 Installation And Servicing Instructions Download

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Osprey 2 CFL

125 - 150 - 180 - 220

Gas Fired Floor Standing Boiler

Installation and
Servicing Instructions

Please leave these instructions with the user

Summary of Contents for Osprey 2 CFL 125

Page 1: ...Osprey 2 CFL 125 150 180 220 Gas Fired Floor Standing Boiler Installation and Servicing Instructions Please leave these instructions with the user ...

Page 2: ...oiler meets the requirements of Statutory Instrument The Boiler Efficiency Regulations 1993 No 3083 and is deemed to meet the requirements of Directive 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purpose of Regulation 5 certified by Notified Body 0049 Product Production certified by Notified Body 0049 For GB IE only ...

Page 3: ...imensions 7 5 0 System Details 8 6 0 Site Requirements 10 7 0 Installation 13 8 0 Commissioning the Boiler 15 9 0 Servicing the Boiler 17 10 0 Changing Components 19 11 0 Illustrated Wiring Diagram 23 12 0 Fault Finding 24 13 0 Short Parts List 28 Section Page Contents ...

Page 4: ...t by a CORGI Registered Installer or other competent person and be in accordance with the relevant requirements of current Gas Safety Installation and Use Regulations the Building Regulations Scotland Consolidation the Local Building Regulations the Current I E E Wiring Regulations and the bye laws of the Local Water Undertaking Where no specific instructions are given reference should be made to ...

Page 5: ...Pipe 14 Pressure Test Point 15 Pilot 16 Overheat Thermostat 17 Boiler Thermostat 18 Inner Front Panel 19 Control Panel 20 Cleaning Brush 21 Heat Exchanger 22 Flue Hood 23 Boiler Safety Overheat Neon 24 Flame Failure Neon 25 Burner On Neon 26 Power On Neon 27 Boiler Safety Overheat Reset 28 Flame Failure Reset 29 On Off Button 30 Temperature Control RESET ON OFF Osprey 2 RESET Fig 2 1 2 3 4 5 6 7 8...

Page 6: ...0 5 06 ft3 h 142 179 180 220 m3 h 6 0 7 3 ft3 h 212 258 Burner Pressure 125 150 mbar 11 2 0 4 11 4 0 4 180 220 mbar 11 0 0 4 11 8 0 4 Inlet Pressure Natural Gas Only mbar 20 in wg 8 Burner Injector 2 6mm Diameter Appliance Type B11BS NOx Class 150 180 3 125 220 2 This value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it h...

Page 7: ...4 0 Dimensions 7 Dimensions mm A 600 695 790 885 Model 125 150 180 220 B 332 5 380 427 5 475 C 850 850 850 850 D 511 511 511 511 E 600 600 650 650 A C B D E Front Side Fig 4 Fig 5 F F 184 184 241 241 ...

Page 8: ...ordance with the guidelines given in BS 7593 Treatment of water in domestic hot water central heating systems This must involve the use of a proprietary cleanser such as BetzDearborn Sentinel X300 or X400 or Fernox Superfloc Full instructions are supplied with the products but for immediate information please contact BetzDearborn 0151 420 9563 or Fernox 01799 550 811 directly For long term protect...

Page 9: ...r flow and return 2 Any bypass must be capable of allowing a minimum flow rate of 8l min and be able to dissipate at least 2kW 5 3 System Control 1 The boiler is intended for use in a heating system that incorporates external controls i e a minimum of a timer device 2 For optimum operating conditions and maximum economy the fitting of room and cylinder thermostats is recommended 3 The boiler shoul...

Page 10: ... Codes of Practice WARNING The addition of anything that may interfere with the normal operation of the appliance without the express written permission of Potterton could invalidate the appliance warranty and infringe the Gas Safety Installation and Use Regulations 6 3 Clearances Fig 6 7 1 Minimum clearances must be provided around the boiler as follows Each Side 150mm Top 700mm Front 700mm Rear ...

Page 11: ...ulations and Building Regulations If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing 6 5 Gas Supply 1 The gas installation should be in accordance with BS6891 2 The connection to the appliance is a 22mm copper tail This is connecte...

Page 12: ...rtment is ventilated as follows 125 models 388cm2 high 125 models 776cm2 low 150 models 478cm2 high 150 models 956cm2 low Both vents must communicate with the same room or be on the same wall to outside air 5 180 and 220 models cannot be fitted in a compartment except of the type specified in BS6644 using a monodraught system 6 The flue system should be lined throughout its length 7 Minimum flue l...

Page 13: ...he retaining magnets and hinge forwards Unhook the panel from the lower hinge pins Fig 10 and place to the right hand side taking care not to stretch the earth wire 6 Remove the flue spigot from inside the case and fit it to the boiler draught diverter Fig 11 Important Only use the flue spigot supplied Do not use a proprietary item 7 Connect the gas supply pipe and the system flow and return conne...

Page 14: ... panel Fig 16 4 Remove the clamps from the panel and slit the grommets with a suitable knife or blade 5 Determine the length of the wiring and secure in the clamps 6 Connect live neutral earth and switched live to L N SL of the terminal strip The pump live neutral and earth should be connected to PL PN of the terminal strip Fig 17 1 4 Securing Screws Top Panel Front Panel Cover Panel Fig 13 Fig 15...

Page 15: ...test point sealing screw and connect a pressure gauge Fig 19 2 Turn on the gas and electrical supplies to the boiler and ensure that all external controls are calling for heat 3 Set the temperature control to maximum Fig 18 4 Check the burner setting pressure see Section 4 0 Technical Data 5 If necessary adjust the pressure by removing the gas valve governor cover and turning the screw to achieve ...

Page 16: ...installation The details of the Log Book will be required in the event of any warranty work The Log Book must be handed to the user for safe keeping and each subsequent regular service visit recorded 3 Instruct the user in the operation of the boiler controls and the function and resetting of the various safety devices 4 Hand over the User s Operating Installation and Servicing Instructions and th...

Page 17: ...rews from the rear of the top panel Remove the panel Fig 22 6 Disengage the front panel from the retaining magnets and hinge forwards Unhook the panel from the lower hinge pins Fig 22 and place to the right hand side taking care not to stretch the earth wire 7 Undo the wing nuts securing the combustion box top panel Fig 23 Remove the panel 8 Undo the disconnecting union on the gas inlet Remove the...

Page 18: ... are clipped into the separation brackets and do not cross over each other 14 Slide a suitable sheet of paper or cloth under the boiler heat exchanger Fig 29 15 Unclip the brush from the top edge of the left hand side panel clean between the boiler fins Fig 28 29 Check for any blockage 16 Carefully withdraw the sheet and dispose of in a proper manner Check under the boiler and remove any fallen di...

Page 19: ...ermostat body Turn the thermostat knob fully anticlockwise and pull it off Fig 33 3 Remove the screws securing the thermostat to the control panel and pull off the earth wire Fig 34 4 Pull the spring clip off the thermostat pocket Withdraw both the boiler and overheat thermostat phials and the spacer tube from the pocket Fig 33 5 Take the new thermostat and turn the operating shaft fully anticlock...

Page 20: ...valve Draw the control off the valve Fig 39 2 Undo the two nuts securing the valve injector manifold and burner assembly to the boiler Fig 40 3 Hold the manifold and carefully draw the assembly away from the boiler Retain the washer from the gas inlet connection 4 Undo the pilot feed pipe from the gas valve and slacken it at the pilot burner to allow it to swing clear 5 Undo the four screws securi...

Page 21: ...asher for each injector 10 6 Pilot Assembly 1 Disconnect and remove the pilot feed pipe Pull the electrode leads off the gas valve burner ignition control and unclip them from the separation brackets 2 Undo the pilot bracket securing screws Withdraw the bracket from the burner mounting plate Carefully remove the pilot injector from the bracket Figs 44 46 3 Inspect the injector and replace if it is...

Page 22: ...inutes 10 8 Burner Ignition Control Fig 50 1 Remove the screw securing the burner ignition control to the gas valve Draw the control off the valve 2 Pull the electrode leads off the burner ignition control 3 Prise apart the three barbs securing the control cover Remove the cover 4 Undo the screws securing the cable clamp to the control and disconnect the edge connector from the control P C B 5 Fit...

Page 23: ...urner ON Neon green Flame Failure Neon Red Safety Thermostat Safety Thermostat Neon red Pilot Assembly Flue Products Safety Thermostat Burner Ignition Control Flame Failure Reset Button ON OFF Button External Pump w 21 w 20 w 28 w 40 w 72 w 71 w 42 w 42 w 61 w 67 b 50 b 50 w 29 w 28 b 50 w 27 b 30 b 50 w 66 b b b ...

Page 24: ... Harness Plug end on Wire Identification W20 W41 linked to H W66 B50 W29 B30 Neutral to N on Terminal Strip W41 linked to B W28 W67 Earth W61 12 1 Fault Finding 1 This page shows the configuration of the plug and socket on the Burner Ignition Control supply Fig 51 The socket is part of the boiler harness and the plug is on the lead connected to the Burner Ignition Control 2 Fig 52 illustrates the ...

Page 25: ... electrical system checks i e Ground Continuity Resistance to Ground Short Circuit and Polarity with a suitable meter Note Repeat these checks after servicing or fault finding 3 Ensure all external controls are calling for heat and check all external and internal fuses Before servicing or replacement of parts ensure the gas and electrical supplies are isolated YES Does the On Off button illuminate...

Page 26: ...Safety Overheat Thermostat connections W28 W29 NO NO Is there continuity across Temperature Control Thermostat connections W20 W21 YES Is there continuity across Flue Safety Thermostat at connections T H on terminal strip YES NO NO YES Does the pump run NO Is there 230V at PL PN on the terminal strip YES Check pump or pump wiring Check boiler internal wiring NO YES Replace pump NO Check flue for b...

Page 27: ...ners light YES Does the boiler shut down when the flow temperature reaches 85 YES NO YES BOILER OPERATING CORRECTLY Is the flame failure neon illuminated Press reset button YES NO Is there 230V at L N connections on the neon Replace the neon YES Is there gas at the burner pressure test point YES NO Remove Burner Ignition Control from valve Is resistance across main solenoid connections V2 3 9 kohm...

Page 28: ...t Key G C Description Manufacturers No No Part No 226 Gas Valve Assembly V501790 201 E03 614 Burner V17000837 228 E03 653 Main Burner Injector V17003199 229 E03 652 Injector Washer V17006504 321 Control Thermostat V133624 234 Safety Thermostat V17006955 215 Pilot Burner Assembly V133535 235 Burner Ignition Control V17000601 322 Flue Products Safety Thermostat V500540 219 Pilot Injector V17003216 2...

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