Potterton Mersey Super Kurzanleitung

INSTALLATION AND SERVICE INSTRUCTIONS

Mersey Super

Gas Fired Water Heater

MY99001A

G.C. NO.52476 38

NON SPOUTED MULTIPOINT MODEL FOR USE WITH NATURAL GAS

THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1984.

“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 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 INSTRUCTIONS WITH THE USER FOR USE ON FUTURE CALLS

IMPORTANT

PLEASE READ THIS BOOK

BEFORE INSTALLING,

OPERATING OR

SERVICING THIS

APPLIANCE.

1. INTRODUCTION - Page 2

The Main Mersey Super is a room sealed instantaneous water heater designed to supply hot water to several outlets which

may be situated in different rooms, but not necessarily at the same time.

The pilot is lit by a piezo spark igniter: no batteries or electricity are required. The main burners will automatically light when

a domestic hot water tap is turned on and go out when the tap is turned off.

This appliance is not suitable for use with a swivel spout.

ENERGY CUT-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 appliance is installed in a compartment, air vents to the compartment at both high and low levels, should be

provided for cooling.

Further guidance is given in BS 5440 Pt.2.

Position of Air Vent

High Low

In compartment which is ventilated to room 274 cm² 274 cm²

42 in² 42 in²

In compartment which is ventilated to outside 137 cm² 137 cm²

21 in² 21 in²

GENERAL

IMPORTANT: The area of wall covered by the appliance must be flat.

The clearances required around the Flue Terminal are shown on the Flue Template supplied with the Terminal Pack.

The appliance must be fitted on an external wall to allow the Flue Terminal to pass directly through the wall to the outside

air.

If the appliance is to be installed into a “SEDUCT” the minimum duct required is 228mm (9in.) deep, 349mm (1 5½in.) wide.

This appliance may take the place of an existing appliance and will mount onto the original flue terminal of any of the

following: AVON, BRISTOL, MEDINA, MEDINA D/L, MEDWAY, MERSEY, SEVERN 3, SEVERN 4, SEVERN 5 and TRENT.

2. TECHNICAL SPECIFICATIONS - Page 3

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.)

Maximum Output 22.7 kW (77,400 Btu/h.)

Flow Rates 6.5 1/mm at 500C rise

Minimum pressure head requirement at water heater * 1 bar (14.6 psi) under flow conditions

Maximum pressure head 13 bar (189 psi)

Gas group G 20

Burner injector (140ff) 1.2mm marking 120

Pilot injector 0.27mm marking A

Nominal burner pressure ** (maximum input) 12.5 mbar (5 in. w.g.)

Connections - Gas

- Water 15mm Copper Tail

15mm Compression

Balanced flues (telescopic) Wall thickness available 100mm - 150mm (4in - 6in) - Part No 31/1 0321

150mm - 230mm (6in - 9in) - Part No 31/1 0322

230mm - 380mm (9in - 15in) - Part No 31/1 0323

380mm - 610mm (15in - 24in) - Part No 31/1 0324

Flue Terminal Guard (Optional) Part No 10/1 0262

Notes:

*Additional external pipework and fittings may affect the resistance and must be taken into account on installation.

** The nominal burner pressure should be 12.5 mbar and will only be obtained if the appliance inlet pressure is correct at

20 mbar even when the appliance is running at full heat input. The meter should be capable of passing 1 00ft3/h of

natural gas plus the requirements of any other gas appliances.

MINIMUM CLEARANCES

Above 60mm

Below 75mm

Sides 5mm (Each)

Front 220mm (To allow for removal of outer case)

For ease of servicing, allow as much clearance as possible below the appliance.

If the appliance is to be installed in a cupboard, the ventilation openings in the cupboard must NOT be blocked. DO NOT

USE THE CUPBOARD FOR STORAGE.

Identification

Badge

Data Badge

420mm

265mm

762mm

Overall

Dimensions

Fig. 1

3. INSTALLATION - Page 4

MY99003A

Flue

Terminal

Keep

(4 - Stud Terminal Shown)

Fig. 2

A. LOCATION

1. If the appliance is to be fixed to a suitable existing

terminal first isolate and remove the old appliance.

Leave the flue terminal in place. Retain the fixing 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.

NOTE: Where the appliance is to be installed into a

SEDUCT the minimum duct required is 228mm (9in) deep,

349mm (15½ in) wide.

Outer Case

Bottom Cover

Bag Of

Accesories

Fig. 3

3. Where the building regulations require it, a flue terminal

guard should be fitted symmetrically around the outer

part of the flue terminal.

4. Unpack the water heater. Find the bags of accessories

before discarding the packaging.

5. Slide off the bottom cover then remove the three

screws securing the outer case and carefully lift it off.

Terminals

With 2 StudsTerminals

With 4 Studs

Cover

Fig. 4

6. Use the self adhesive discs supplied to cover the

unwanted fixing holes in the back of the new appliance

as shown.

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 appliance.

8. Lift the appliance into position, locating the flue outlet

into the circular duct on the flue terminal.

9. Secure with the appropriate nuts and washers.

Fig. 5

B. GAS CONNECTION

IMPORTANT: Blow out all foreign matter from the supply

pipe before connecting to the gas service cock.

15mm copper pipe to BS 2871 may be used for a simple

supply not exceeding 3 metres (10ft) from the gas meter.

Where the installation contains many bends or the length is

in excess of 3 metres (l0ft), then the use of 22mm copper

pipe is necessary.

1. Assemble the filter, ‘O’ ring and inlet tail to the gas inlet.

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 supply.

5. Turn ON the gas supply and the gas service cock then

test for gas soundness (BS 6891).

IMPORTANT: DO NOT TRY TO LIGHT THE APPLIANCE

AT THIS STAGE. TO ALLOW THE MAIN BURNER TO

IGNITE WITHOUT THE OUTER CASE SECURED IN

POSITION IS A HAZARD.

MY99022A

OFF

Gas Inlet

Gas Filter

'O' Ring

Gas Inlet Tail

Gas Service Cock

On / Off Screw

Fig. 6

INSTALLATION - Page 6

Fig. 7

C. WATER CONNECTIONS

IMPORTANT: Flush out all foreign matter from the supply

pipe before connecting to the service cock.

1. Assemble the filter, olive and inlet tail to the water inlet.

NOTE: The inlet tail need not be used as a vertical

supply can be routed directly onto the water inlet.

2. Depending on whether the main supply pipe is to be

routed vertically or horizontally to the appliance,

connect the water service cock either directly to the

water 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 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 to flow. Purge the air from the system by closing

the hot water outlets starting with the lowest level and

ending with the outlet at the highest level.

6. Check for water leaks and remedy if found.

IMPORTANT: DO NOT TRY TO LIGHT THE APPLIANCE

AT THIS STAGE.

MY99008A

Filter Guaze

Union Nut

Pilot Tube

Fig. 8

D. LINT FILTER

This appliance has a lint filter fitted around the

base of the pilot tube.

Ensure that the filter gauze is located inside both end caps

and that the complete assembly is correctly seated over the

union nut at the base of the pilot tube.

4. COMMISSIONING - Page 7

WARNING: The outer 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).

MS99004A

Outer Case

Fig. 9

2. Ensure that the gas and water supplies are turned ON.

3. Ensure that all hot water outlets are closed.

4. Remove the screw and sealing ring from the burner

pressure test point and attach a pressure gauge.

Fig. 10

5. Fully depress and hold the ON button ‘ ’and

repeatedly press and release the IGN button ‘ ’until

the pilot is lit. The pilot flame can be observed through

the pilot viewing window.

6. Hold the ON button ‘ ’in 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 (5 in w.g.), if

the pressure is not correct see the FAULT FINDING

section.

Fig. 11

COMMISSIONING - Page 8

Fig. 12

NOTE: If a gas rate check is required, the gas consumption

after 3 minutes running should be approximately

48.5 l/mm (1.7³/min).

9. Turn OFF the hot water outlet and press the 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.

Fig. 13

Explain to the user how to operate the appliance.

- see the “Instructions for Use” booklet.

Show the user the position of the Identification Badge.

HAND OVER THE “INSTRUCTIONS FOR USE” TO THE

USER.

LEAVE THESE “INSTALLATION AND SERVICE”

INSTRUCTIONS WITH THE USER FOR USE ON FUTURE

CALLS.

ADVISE THE USER THAT FOR CONTINUED EFFICIENT

AND SAFE OPERATION OF THE APPLIANCE, IT IS

IMPORTANT THAT SERVICING IS CARRIED OUT AT

INTERVALS RECOMMENDED BY THE LOCAL BRITISH

GAS REGION OR C.O.R.G.I. REGISTERED INSTALLER.

5. SERVICING - Page 8

To ensure continued efficient operation of the appliance, it is recommended that it is checked and serviced as necessary at

regular intervals. The frequency of servicing will depend upon the 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 regreasing.

SERVICING - Page 9

Operate the appliance noting any faults in the component

units. Carry out the servicing procedure then correct any

other faults by reference to ‘Replacement of Parts’, in which

section you will find details of how to dismantle and

reassemble the following detailed components. Check that

the burner ignition is smooth and quiet when a hot tap is

opened. The burner ignition has been factory set and should

not need adjustment. However, if adjustment is required a

slow ignition screw is fitted to the appliance and is situated

above the cap screw in the water governor body (fig. 16).

The screw is factory set 2 full turns out (anti-clockwise) from

the fully in position. Turning the screw clockwise delays the

ignition, anti-clockwise advances the ignition.

WARNING: NEVER OPERATE THIS APPLIANCE WITH

THE OUTER CASE REMOVED.

MS99016A

Push Rod and Seal

Pilot Injector

Burner

Assembly

Thermocouple

Fig. 14

1. Check the 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 using Dow Corning 111 silicone grease.

5. Check for water and gas soundness. Replace ‘O’ rings,

sealing washers and gaskets where required.

Water Governor

Flame Safety

Device

MS99005A

Fig. 15

6. Clean any deposits off the heating unit by washing or

brushing. Descale the heating unit if required.

Fig. 16

6. REPLACEMENT OF PARTS - Page 10

IMPORTANT: THE FOLLOWING WORK SHOULD ONLY BE CARRIED OUT BY A COMPETENT SERVICE

ENGINEER. E.G. BRITISH GAS OR CORGI REGISTERED PERSONNEL

1. IF WATER IS DRAINED FROM THE SYSTEM DURING SERVICING, 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.

START

General Access/Main Burner

Remove Piezo Unit

Remove Pilot Injector

Remove Thermocouple and

Electrode

Remove Pilot Injector

Remove Water Governor and

Push Rod

Remove Energy Cut-Off Device

Drain the Appliance

Descale and Regrease

Remove Heating Unit

Remove Flame Failure Device

Remove Water Govenor

Venturi

Descale Heating Unit

Remove the Automatic Valve &

Burner Manifold Complete

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