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~

80 -2350

kW

High Efficiency, Welded Steel, Gas or Oil (Class D) Boiler

September 2000

INDEX
Page No. SECTION 1 Figure 1.1 Table 1.1 Table 1.2
-General Data & Dimensions -Boiler Dimensions (mm) -Combustion Chamber Data

1.1 1.1
1.'2

BOILER & BURNER POWER

SUPPLY
Table 4.2 Figure 4.6 Figure 4.7 Figure 4.8 -Minimum Burner Tube Length -Boiler & Burner Power

CLEARANCES

Figure 1.2
Table 1.3 Table 1.4

-Boiler Clearances -Boiler Base Dimensions -Technical Data

1.2 1.2
1.2
1.3

4.3 4.3 4.4 4.4


4.4

Supply
-Burner Cable Conduit Fixing -Boiler Control Panel Wiring Connections BOILER CONTROL PANEL -Control Panel Layout -ControlPane.l Assembly -Hours Run Meter Assembly -Installation of Controller -installation of Heat Exchanger Insulation Blanket

SECTION 2 GENERAL STANDARD SUPPLY INSTALLATION BOilER SITING & BASE SYSTEM WATER QUALITY 2.1 2.1 2.1 2.2 2.2

4.5
4.5 4.6

Figure Figure Figure Figure Figure

4.9 4.10 4.11 4.12 4.13

4.6
4.6 4.7

SECTION 3
ELECTRICAL VENTILATION SUPPLY 3.1

SECTION 5
BOILER COMMISSIONING FAULT FINDING BOILER MAINTENANCE

(
5.1
5..2

FUELSUPPLY FLUE
FLUE SIZE CONSIDERATIONS FAN DILUTION SYSTEMS -Flue Resistance Losses Guide -Flue Resistance Losses Guide -Flue Dilution SystemsDuct Sizes & Fan Volumes WATER CIRCULATION

3.1 3.1 3.2


SECTION 6

5.3

3.3 3,4

Table 3.1a

Figure 6.1 Figure 6.2 Figure 6.3 Figure 6.4 Figure 6.5 Figure 6.6

-Boiler Wiring Diagram -Schematic Control Panel Logic Diagram -Volt Free Contact Connections -Optional LocalfRemote Switch Wiling -Pump Overrun Using Changeover Pipe Thermostat -Bumer Connection Wiling

6.1
6.2 6.3

Table 3.1b Table 3.2

3.6
3..7

3.8
3.9 3.9 3.10 3.10 3.11 3.11 3.12 3.12 3.13

6.3
6.4 6.4

SYSTEMS Table 3.3 Table 3.4 Table 3.5 Table 3.6


BOILER PROTECTION -Saturated Steam Pressures -Cold Feed Pipe Sizes CISTERN SIZING -Open Vent Pipe Sizes -Safety Valye Sizes SEALED SYSTEMS NOISE LEVEL

SECTION 7

Figure 7.1 -BoilerComponents BOilER PARTS LIST Figure 7.2 -Control Panel Components CONTROL PANEL PARTS LIST COMMISSIONING SHEET

7.1 7.2 7.3 7.4

SECTION 4
BOILER INSTALLATION -Inside View of Boiler Combustion Chamber Door -Number Of Turbulators -Insta.lJation of Turbulators and Location of Boiler Control Panel -Control Panel Mounting -Phial Pocket Location -Burner Tube Installation

4. 4.1
4.1

Figure 4.1 Table 4.1 Figure 4.2

Figure 4.3 Figure 4.4 Figure 4.5

4.2 4.2
4.2

4.3

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

Section 1

Page 1.1

ARIZONA

Fiaure 1.1 -General

Data & Dimensions


RETURN L5 L1 FLOW

L3

r4

H2

H11

H31

-1-141

---r -~ A1 ~
I !

A1 ~~
I
3/4" CONDENSATE

-r~-A3

I
DRAIN

L6

~IL7

1 1/4" BSP DRAIN

Table 1.1 -Boiler

Dimensions

(mm)

L1 1289 140 170 200 250 290 350 405

L2

L3

L4*

L5

l6

L7

H1

H2

H3

H4

A1

A2

A3

9981_]289 998
~~ .I 810 I ~ 1 900 1101~1150 11025-1 950 I 500 -I 100 1 283~1 50 I 998-

1289 I 250 , 810 I 900 , 900

150 I 1025 I 950 I 500 I 100 I 283 I 50 150 I 1025 I 950 I 500 I 100 I 283 I 50

I 998 I 998 129011~ 1484

1289 I 250 I 810 , 900 ! 900


157

1~2 I 350 11200! 1100 11100 11500 I 200 11300 11150! 1962 2240 2240 2240 I 350 I 1500 1250 I 1800 I 200 , 1450 1,1300 I ~ 1250, 1250 11800 I 200 i 1450 11300 I

600 i 100 I 423 I 50 I 423 I 50 423 423 675 , 100 I 423 I


50 50

11484 I 1484
.11484 11784

1962 I 350 I 1200 I 1100 I 1100 11500 ! 200 I 1300 I 1150 I 600 1100

465

350 11500 11250 11250 I 1800 I 200 I 1450 11300 I 675 I 100 I 423 I 50 675 I 100 I 423 I 50
( 100 I 523

I 1784 \ 1784 11784 /1784


I 1784
.I 2130

50 11784

t-

12240

350 I 1500

I 2255 I 400

11500 I 1450 11450 I 1800 I 250

i 1650 11466 I 766

50 50
50
50

523 523 2680' 450 I 1750 11750 , 1750 I 2150 I 250 I 1950 I 1800 I 925 , 100 I 673 2680 I 450 I 1750 11750 , 1750 I 2150 I 250 I 1950 11800'

925 I 100 I 673 I 50

,I2130 I 2380 380

2900 I 450 I 2000 ! 1900 11900 I 2400 I 250 I 2125 11970 ! 1020 I 180 I 703 I 91 2900 I 450 ! 2000 i 1900 I 1900 .I 2400 I 250 I 2125 11970 j 1020 I 180 I 703 I 91 3100 91

2580

See boiler clearances on page 1.2. The clearance required in front of the boiler is either L4 or P + 1000mm whichever is the greater.

~
~

1.12891 11010 I ! I1Q1O"

Section 1

Page 1.2

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION,. OPERATING & MAINTENANCE MANUAL

ARIZONA
Table 1.2 -Combustion Chamber Data

CLEARANCES
The minimum boiler room clearances for access, erection and maintenance are given in Figure 1.2 and Table 1.3. There is no minimum clearance above the boiler however, it is recommended that clearance is left above the top of the instrument panel for access. "POI is the burner projection of the selected burner. NOTE: The Arizona boiler combustion chamber door is hinged on the right hand side and will open to the right hand side only.

";;
'1i

~ i~
\'1

Fiaure 1.2 -Boiler Clearances

CLEARANCE IN FRONT OF BOILER EITHER L4 (SEE TABLE 1.1) OR P + 100(lv1M WHICHEVER IS THE GREATER

500mm MINIMUM

J:-a-ble1.3 -Boiler Model


W 1000

Base Dimensions
L 1200 1200 1200 1200 1200 1300 1700 1700 1700 1700 Model 580 640 700 800 900 1100 1400 1650 1850 2100 2350 W L

80
100

1300
1300

2000
2000 2000 2000 2000 2000 2240

1000
1000 1000

I.-

140

1300 1500 1500 1500 1800 1800 2000 2000 2200

170
200 260 290 350 405

1000 1200 1200 1200 1200 1200 1300

2240 2500
2500 2800

465

520

2000

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL ARIZONA

Section

Page 1.3

Table 1.4 -Technical

Data

See notes on page 1.5

Section 1
Page 1 .4

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA Table 1.4 -Technical Data

See notes on page 1.5

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

Section 1

Page 1.5

ARIZONA

FUEL CONSUMPTION Gas fuel consumption is based on natural gas with a gross calorific value of 38.6 MJ/m3, refer to relevant burner data sheet for minimum and maximum fuel pressures. The g~s rate should be corrected for the meter supply pressure on high pressure supplies to prevent over-firing. Oil fuel consumption is based on Class D (35 second) gas oil with a gross calorific value of 45.5 MJ/kg, refer to relevant burner data sheet for minimum and maximum fuel supply pressures.

2.

(a)

MAXIMUM OPERATING

PRESSURE

The maximum operating pressure is 5 bar. As an optional extra the boiler can be supplied with a maximum operating pressure of 10 bar on request. (b) MINIMUM OPERATING PRESSURE This is the minimum operating pressure of the boiler with pumps operating (NOT static pressure). The requirements of the Health & Safety Executive guidance note PM5 regarding maximum operating temperatures should be observed.
3.

BOILER FLUE CONNECTION This is the nominal flue size of the flue connection spigot. Actual flue size required to achieve evacuation of the products of combustion under all running conditions should be calculated and may need to be increased.

FLUE GAS VOLUME Flue gas volumes are given at STP (standard temperature and pressure, 15C and 1013.25 mbar respectively). Typical CO2 levels are, 9% -gas firing, and 12% -oil firing. Flue gas temperatures stated are at nominal output (kW) under the following conditions, Ambient temperature 20C, excess air 20%, flow temperature 80C and return temperature 60C.

5.

NATURAL VENTILATION The sizes indicated are free grille areas and are based on a single boiler installation,

6.

MECHANICAL

VENTILATION

The volume given is for a single boiler instal/ation. WATER CONNECTION SIZES

The boiler water connections are 2" BSP on models 80 to 250 and flanged (PN6 standard, PN16 for higher operating pressure option), on all other models. Counter flanges are not provided. 8.

WATER FLOW RATES Water flow rates are given for boiler flow and return temperature difference of 11C.
COLD FEED/OPEN VENT/SAFETY VALVE SIZES

Sizes indicated are minimum sizes for single boiler installations. Safety valve sizes are for use with open vented systems only. see BS 6644 for sealed system requirements.

10

MINIMUM RETURN TEMPERATURE


This is the minimum operating return temperature to prevent condensation system. See section 3 for further details on back end protection. within the boiler

11

WEIGHT
The dry weight is exclusive of the burner and gas train, see burner manufacturers relevant burner weights. literature for

7.

'
I ,; j

Section 2

Page2.1

POTTERT'ON COMMERCIAL PRODUCTS DIVISION INSTALlATION, OPERATING & MAINTENANCE MANUAL

!;

ARIZONA
The standard boiler is factory tested to 7.5 bar with a maximum working pressure of 5 bar. Boilers can be The Potterton Arizona is a high efficiency steel supplied ~rith a maximum working pressure of 10 boiler in 22 sizes offering heat outputs from 80 to bar (test pressure 15 bar) on request.

1 ,w,

7I[

GENERAL

2350 kW Packaaina The Arizona is a one piece boiler has been specially developed for the public and commercial sectors. The boiler is delivered in 4 packages as follows:Compact dimensions mean it can ber easily and .Boiler heat exchanger complete (including 1 st quickly installed in existing or new boiler houses. layer Iboiler insulation blanket).
.Contrlol panel, fittings bumer mounting ceramic Net efficiency of 92% is obtained through the large fibre insulation -located inside the combustion two pass reverse flame combustion chamber design chamber with high efficiency turbulators and a pressurised .Casing pack (including 2nd layer boiler combustion chamber together with double layered insulation blanket). insulation producing minimum case losses of less .Bumer than 0.5% of boiler output.

DeliverY The boiler is available for use with natural gas or 35 second oil. Note that

specialist lifting equipment may be required to position the boiler on site, (especially for A comprehensive control panel is provided to allow larger models). Two lifting eyes are fitted to the easy control of the boiler with an option for boiler for this purpose.

monitoring via a BMS.


STANDARD SUPPLY

INSTALLAI!QN

Steel boiler shell (operating pressure 5 bar, test The installation should comply with relevant British pressure 7.5 bar) Standard :Specifications, Codes of Practice and High efficiency turbulators current Building Regulations, together with any Flueway cleaning covers special rE~gional requirements of the Local Double insulation comprising 2 x 50mm Authorities, Gas Undertaking and Insurance insulation blankets Company. All electrical wiring must comply with Painted chequer plate boiler top I.E.E. ReglLJlations for the Electrical Equipment of Boiler casing Buildings. Burner adapter plate and gasket Control Panel The installation of the boiler must be in accordance Matched oil, gas or dual fuel burner with the rel~evant requirements of:Casing colours BlackRed Health & Safety at Work Act 1974,

Control Panel
.Thermometer .1 st Stage thermostat .2nd Stage thermostat .Overheat thermostat .Power on indicator light .Overheat indicator light .Burner on/off switch .Overheat thermostat test switch .6.3A fuse .1 st Stage run indicator light .2nd Stage run indicator light .Burner lockout indicator light .Pump on/off switch .On/off burner connection cable .High/low burner connection cable .1 st Stage hours run meter .2nd Stage hours run meter

CP331:3 Low Pressure Installation Pipes. BS 6644: 1991 Installation of Gas Fired Boilers. BS 7074: 1989 Part 2 Application, Installation of Expansion Vessels Equipment for Sealed Water Systems. Selection & & Ancillary

PM5 Health & Safety Executive Guidance Note for Automatically Controlled Steam & Hot Water Boilers.

CP341 :300..307 Central Heating by Low Pressure Hot Water.


CP342:2 C4~ntralised Hot Water Supply.

...
! ~ ..

....

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL ARIZONA

Section 2

Page2.2

Also for gas fired appliances the following British Gas publications:When preparing a site, reference should be made to
Gas Safety (Installation & Use) Regulations 1984. Local Authorities and Building Regulations 1992. The Arizona boiler is not suitable for installation in

IM/11 Flues for Commercial and Industrial Gas kitchens or living areas. Fired Boilers and Air Heaters.
IM/2 Purging

Procedure

for

Installations.
IM/S Soundness

Non-Domestic SYSTEM WA IER QUALITY Non-Domestic good


To ensure the boiler heat exchanger remains in condition it is essential to condition and monitor the system water to the following criteria:-

Installations.

Testing

for

In the event of a gas booster being necessary refer to IM/16 'Guidance Notes on the Installation of Gas Pipework, Boosters and Compressors in Customers Premises' and the Gas Act 1972, Schedule 4, Paragraph 18. Manufacturers notes must not be taken in any way as overriding statutory obligations.

Water Hardness
If the system fill water has a hardness in excess of 250mg/1 (17.50 Clark) the water should be softened prior to filling the system to ensure that excessive scaling does not occur within the heat exchanger.

2. Water Acidity
The system fill water should have a pH value between 7 -8.5 to ensure corrosion of the heat exchanger does not occur. 3. Free Oxygen The free oxygen content of the system water should be zero. (When testing for oxygen content the sample should be tested immediately it is drawn from the system to ensure a true reading is obtained). Iron Ions/Oxides Iron content of the system water should be less than 0.1 lng/I. Iron ions are colourless, if iron is a serious problem then iron oxides, FeZO3 and Fe3O4' coloured red and black respectively may be produced.

In addition for oil fired appliances refer to the following:BS 799: Oil Burning Equipment For boilers with a heat input rating greater than 2MW the provisions of BS 6644 have been adopted as the best practice.

BOILER SITING AND BASE


The boiler should be sited in accordance with BS 6644: 1991 with respect to protecting the boiler from damage, air for combustion and ventilation, discharge of products of combustion, clearances for service and access, temperatures, noise levels, the disposal of boiler water and flooding of the boiler house or seepage from a roof top boiler house. See figure 1.2 for boiler clearances for service and access and table 1.3 for boiler base dimensions.

A level non-combustible floor capable of supporting the weight of the boiler filled with water, see Table 6. 1.4, together with any additional weight bearing down on the base from connections, burner, etc, must be provided.

5. Sulphates Sodium Sulphate is the principal component of water treatment. Inclusion in the water system ensures dissolved oxygen is removed and the system is protected against corrosion. Copper Ions
The copper content of the system water should be less than O.OSmg/l. If large quantities of copper are present red and black copper oxide Cu20 and CuO and, grey/green copper carbonate, CuCO3 will be produced. Copper will corrode iron and aluminium within the system.

The weight of the boiler is supported by two "C" section supports fitted to the bottom of the boiler, see figure 1.1 and table 1.1 for support dimensions.

For certain special installations a sound proof plinth IMPORTANT: llnder no circumstances should may be necessary and a metal plinth resting on raw make-up water be allowed to be regularly anti-vibration pads is recommended in these! introduced into the system. instances. i

I 4.

Section 3

Page 3.1

POTTER-IrON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA ELECTRICAL SUPPLY


On oil distribution systems with long pipe runs or when the oil tanks are mounted at a lower level than the burner, consideration should be given to the use of a pressurised ring main. The individual boiler connections to the ring main should incorporate pressure regulating valves to maintain a constant pressure to the burner below the maximum inlet

The Arizona is supplied with both single phase and three phase burners. The boiler installation should be connected via a fused isolator. For a three phase installation a separate 230V 50Hz single phase electrical supply should be taken to the boiler instrument panel. This is fused 6.3A in the pressure. instrument panel. See figure 4.6, page 4.4. All on site wiring shall conform to I.E.E. Regulations. .B.!ELSUPPLY

~I!.UrnQN

Safe, e'ffjcient and trouble free operation of conventionally flued boilers is vitally dependent upon the provision of an adequate supply of fresh NATURAL GAS air to thE! room in which the appliance is installed. Account must also be taken of any other fuel Where there is an existing primary gas meter, the burning appliance existing or to be fitted when appropriate gas supplier/undertaking must be designin~1 the ventilation and combustion air

consulted to ensure that the service/meter supply systems. capacity is adequate for the proposed installation.
For gas burner connection sizes refer to the burner card or burner manufacturers instructions. Note that elevated gas pressure may be required, particularly for the larger models, (a gas booster may be required). Ensure that the required gas volume at the correct pressure is available. The gas supply pipe should be sized to allow the minimum operating pressure to be available at the bumer inlet under full running conditions. The pipe should be sized to prevent excessive pressure drops under full running conditions. The air slupplied for boiler house ventilation shall be such that the maximum temperatures within the boiler house shall not exceed 25C at floor level, 3~C at mid level (1.5m above floor level) and 40C at ceilin~J level (or 100mm below ceiling level). Refer to 1356644: 1991 for further details. Air SUDDlv bv Natural Ventilation Ventilation by grilles communicating directly with the outside air is required at both high and low levels. A minimum free area of the grilles for a single boiler are given in Table 1.4. Where plant is likely to used at or near maximum capacity during the summer months, additional ventilation may be required to prevent excess temperatures.

Where gas boosters are required attention is drawn to the Gas Act 1986, Schedule 5, Part II, paragraph 8 (4). Guidance is given in IM/16 "Guidance Notes on the Installation of Gas Pipework, Boosters and Compressors in Customers Premises" published by For boiler houses with multiple boiler installations British Gas Pic. The gas booster should be the minimum ventilation should be sized in electrically interlocked to the burner. accordam:e with BS 6644 as follows:GAS OIL (CLASS "0") Each burner is provided For boilers up to 300kW with a positive head is excess of this output should be consulted. with an integral fuel pump. output a single pipe system adequate. For boilers in the burner manufacturer

Low Level (inlet) -

540 cm2 plus 4.5 cm2 per kW in

excess of 60 kW total rated input.


Hiah Level (outlet) -270 cm2 plus 2.25 cm2 per kW in excess of 60 kW total rated

input.
The abov'e calculated areas are "free" grille areas. Grilles should be designed to minimise high velocity air strearns within the boiler house. Typical free area of a standard louvre is a~.proximately 50%. For boilers installed in a basement boiler house similar, it is recommended that the inlet air ducted to low level in ducting not less than equal the free grille area. Should the inlet duct length or be to be

Each burner is provided with a fuel filter for installation local to the burner. Refer to burner manufacturers information pack supplied with each burner for connection details for one and two pipe operation. Oil distribution pipes should be sized to maintain positive pressure at the burner inlet where possible.

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

Section 3 Page 3.2

ARIZONA

excessive

then

mechanical

ventilation

should

be

used.
Position ventilation grilles to avoid obstruction by blockage or flooding. accidental

isolate the boiler from the area by situating it in a separate area where fresh air can be introduced.

Care should be taken in positioning extract ductsI from contaminated areas in relation to boiler house grilles to ensure that cross contamination will not Fur1her guidance on ventilation for gas appliances is occur. provided by BS 6644: 1991.

E!::Y5
Air Supply by Mechanical Ventilation The supply of air to a space housing the boiler by mechanical means should be by mechanical inlet with natural or mechanical extraction. Mechanical ventilation with natural inlet must not be used. See Table 1.4 for mechanical inlet ventilation rates for single boiler applications To ensure safe and satisfactory operation the chimney system, which may be individual or common in the case of modular boiler installations, shall be capable of the complete evacuation of combustion products at all times. The effectiveI height of the chimney terminal(s) above the boiler(s) flue outlet(s) shall ensure sufficient buoyancy to overcome the resistance of the bends, tees and runs For multiple boiler installations the ventilation rate is of the flue pipe involved and shall terminate in aI based on a 0.9 m3/sec flow rate per 1000 kW total down draught free zone. The number of bends used rated input. The design extract rate should be should be kept to a minimum and runs of flue pipe based on 0.6 m3/sec flow rate per 1000 kW total less than 450 to the horizontal should be avoided in order to comply with the recommendations made in rated input. BS 6644: 1991, British Gas publication IM/11 "Flues for Commercial and Industrial Gas Fired Boilers and For mechanical ventilation systems, an automatic control should be provided to cut off the supply of Air Heaters". The third edition of the 1956 Clean Air fuel to the boiler(s) in the event of failure of air flow Act Memorandum and the Building Regulations in either inlet or extraction fans. should be strictly observed and approval obtainedI where applicable, combustion chamber details are IMPORTANT: The use of an extractor fan in the given in Section 1, Table 1.2.

same room as the boiler (or in an adjacent room in communication) can, in certain conditions, The chimney design should avoid the formation of adversely affect the safe operation of the boiler condensate which may be achieved by insulating the flue. Typical flue gas temperatures for the and th:refore must be avoided.
Arizona boiler are given in Table 1.4. Tests for spillage of products from the flue system when the extractor fan is running and all doors ana windows are shut should be carried out during commissioning. If spillage is detected, the area of permanent ventilation must be increased. In the case of flue systems which are exposed and have an overall height of 12m or more then consideration should be given to lining the flue. In the case of brick or similar structures a stainless steel rigid or flexible flue liner (Grade 304/316) may be used backed up with a 50mm minimum thick layer of vermiculite or perlite granules between the inner skin and the chimney body. Cavities around the liner should be sealed at both top and bottom. A flue system should be no nearer than 50mm to combustible material except where it passes through it enclosed in a sleeve of non-combustible material with an annular (air) space of 25mm. The flue termination should be at least 1 m above the roof surface and away from any wind pressure areas where the flue products could re-enter the building, ego near an openable window, mechanical air inlet, etc. Flues should not be terminated inI areas where down draught may occur.

Contaminated

Combustion Air air is

It is essential that fresh and uncontaminated introduced to the boiler for combustion.

Air contaminated with chlorine vapours and CFC gases must not be allowed to enter boiler combustion chambers or formation of chlorine gas and hydrochloric acid will create severe and rapid boiler corrosion. There is also a danger that toxic chlorine gas will be emitted from the boiler flue. In areas where such products are used, and these include degreasants, dry cleaning fluids, refrigerants and aerosol propellants, steps must be taken to

Section 3

Page 3.3

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALlATION, OPERATING & MAINTENANCE MANUAL

ARIZONA

iMPORTANT: 900 square bends must not be used on the flue system, including the boiler flue spigot, a straight length followed by an "easy sweep" or lobster back bend should be used.
On multiple boiler installations where a common flue header is utilised. boiler connections to the flue header and connection of the flue header to the chimney stack should utilise 1350 swept "T" connections. Drainage points positioned at the bottom of all vertical chimney sections should be provided. Drain pipes should be no less than 25mm 1.0. and should be manufactured from acid condensate resistant material such as high temperature polypropelene or stainless steel and positioned so that pipe runs and discharge points are not subject to the effects of frost. Copper pipe is not suitable due to the mildly acidic properties of the condensate. Condensate pipe runs should fall with a gradient of at least 3% and at no point must the drain pipe rise above the level of the drainage point connection.

Where the flue draught is inadequate to meet the minimum boiler flue draught requirements or excessive horizontal runs of flue have been utilised that may prevent satisfactory start-up of the boiler and flue system, then mechanical assistance should be considered. The buoyancy force is directly proportional to the flue gas temperature of the exhaust gas. The flue system should be designed, and insulated where necessary, to maintain a temperature drop of less than 17C between the flue gas entry and flue gas exit. For flue calculation purposes the mean flue gasI temperature is equated from flue gas temperatureI (net) + ambient temperature -17C/2 (this assumesI a maximum temperature drop of 17C across the flue system and represents the mean temperature). For example the Arizona Model 140 has a typical flue gas temperature of 170C (net). Assuming an ambient temperature of 20C a typical mean flue gas temperature for this boiler would be:-

170 + 20 -11 = 181.5C

Net flue gas temperature = gross flue gas A draught of 0-4mm.w.g. (0-0.16 in.w.g.) should be ~: temperature -ambient provided at the flue socket under full load running conditions. The flue system should be designed to evacuate the products of combustion when all The buoyancy force available due to the vertical boilers are firing. The Local Authority should be height of the flue can be calculated as follows:consulted with regard to Clean Air Act approval.

1 -tz+273 -L B = 353 x H x t"+2=t3


FLUE SIZE CONSIDERATIONS Nominal boiler flue connection sizes are given in Table 1.4 these sizes refer to the boiler flue connection spigot. The actual size of the flue system will depend on individual site applications. Detailed below are general considerations on sizing flue systems. These notes are for guidance only and Potterton Commercial Division cannot accept responsibility for flue system design.

where: B = H= t1 = t2 =

Buoyancy force in mmwg Stack height in m Ambient temperature C Mean flue gas temperature C

For an Arizona boiler buoyancy force is typically 0.4 mmwg (80 model), 0.41 mmwg (100 -170 models) and 0.43 mmwg (180 -2350 models) per metre stack height measured vertically from the flue I connection on the boiler to the chimney exit point.

Natural Drauaht Flue Systems Buoyancy Force Natural draught flue systems are designed so that the buoyancy force due to the hot flue gases create a draught (suction) that, after overcoming resistance losses, is adequate for the flue draught requirements at the boiler connection spigot given in Table 1.4. Flue System Losses Losses in flue systems are attributed to friction losses due to flue gas velocities, plus pressure losses due to fittings and the chimney exit point. Table 3.1 (page 3.6) gives the pressure loss for each metre of flue pipe and the pressure drop forI each flue fitting. The flue system pressure drops should be totalled including all horizontal flue runs and the chimney exit loss.

..

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

Section 3

Page 3.4

ARIZONA

Subtraction of the total loss from the buoyancy available will give the flue draught available at the boiler flue outlet spigot. The flue system should be sized so that the draught available is within the operating range of the boiler as given in Table 1.4.

Excessive Buoyancy Force To reduce a high flue draught to an acceptable operating level, consideration should be given to the installation of a flue draught stabiliser.

Horizontal Flue Runs

Common Flue Systems

Horizontal flue runs are not recommended! Where multiple boilers are installed on a common particularly over 3m in length, where these are flue system then the flue system should be designed unavoidable advice should be sought from a flue I to ensure the correct operation of the flue on varying system specialist. I load conditions. In particular that the appliance flue draught is within the operating parameter under full load and partial load conditions. For safe and reliable operation of the boiler plant it is Cold Start Considerations recommended that the variance in flue draught When the boiler starts up from cold no flue draught I available at each appliance under full and part load is available due to buoyancy and therefore the I operation is designed to a minimum. burner has to overcome the total resistance loss resulting in a positive pressure at the base of the (It is recommended that the services of a flue equal to the total resistance loss as calculated specialist flue system manufacturer are sought from Table 3.1. Following start up of the boiler a for the design of common flue systems). flue draught, as calculated above, is available at the boiler flue connection spigot. This start up sequence results in the burner operating with a flue Mechanical Assisted Flue Systems draught that can vary between P1 (positive flue pressure) and P2 (flue draught), ego for a system Where mechanical assisted flue systems are being with a total resistance of 5mm and a hot flue considered it is recommended that the advice of a draught of 3 mm (-3 mm pressure), the burner would flue system specialist is sought to ensure the duty be subject to a variance in flue draught on start up and suitability of the fan. On mechanically assisted flues the boilers must be interlocked to prevent of 8 mm. I operation unless the fan is operating and air flow is

proved.
(P2) (P1)

Flue Draught -3mmwg

Flue Resistance 5mmwg

FAN DILUTION SYSTEMS Potter1on Commercial gas fired boilers are suitable for fan dilution systems for low level discharge of products of combustion in accordance with BS 6644. The fan dilution system should be designed to reduce the CO2 concentration of the vented combustion products to 1 % (volumetric) or less.

I ~

9 Total variance8mmwg~

For reliable operation of boiler plant and in particular on oil fired appliances, to prevent premature sooting I of the boiler the variance in resistance on boiler start The discharge velocity from the fan dilution system up should be kept to a minimum and is not I should be a minimum of 7.5 m/sec and should be at recommended to exceed 6 mm. For example on a i least 2m above ground level for systems up to 1 MW long, thin, tall flue system the cold start resistance is input. high but, due to the height, the flue draught available under full running conditions is also high The outlet grille should diffuse the products of resulting in an unacceptable variance in flue gas combustion upwards and be located so that conditions. To reduce the cold start resistance re-circulation of combustion products is avoided, in consideration should be given to increasing the flue particular the positioning of fan dilution systems in sizes or soft starting of the boiler plant and flue totally enclosed wells or courtyards should be system by operating boilers on low fire only for a avoided. The inlet and outlet grilles must be located on the same face of the building. pre-determined period.

Section 3

Page 3.5

POTTERTON CO~'MERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL ARIZONA EXAMPL~

Fan dilution systems must be interlocked to prevent operation of the boilers unless adequate air flow is

proved.
In accordance with BS 6644: 1991 the position of the outlet grille should comply with the following:1. The outlet grille shall not be less than 2 x 'U'm from any fan assisted intake, where 'U' is the un-corrected chimney height in metres, as defined in the Clean Air Act and is calculated from:'U' = 1.3 QO.6
(\,

.300mm Dia

--.
I! -

:ii;

~
E co

TT

c;:::

~
2 x 45' bends to

Arizona Model 520

(where '0' is the heat input in MW)

form easy sweep bend

2. The outlet shall not be within 2 x 'U' of an openable window or 6 x 'U' from an adjacent An Arizona Model 520 boiler connected to a 300mm diameter flue 6 metres high, net flue gas building. temperature 180C. The flue draught is calculated 3. The fan dilution system should be designed to as follows from table 3.1:provide a flue draught at each boiler of 1-2

m.m.w.g.
Typical duct sizes, fan volumes are given in Table 3.2. and values of 'U'

Flue exit loss 450 bend loss (2 x 0.1575) Straight flue loss (6 x 0.0632)

0.7874 mmwg

0.3150 mmwg 0.3792 mmwg 1.4816 mmwg

Total flue pressure loss (P1)

It is important that adequate ventilation is provided into the boiler house especially as a proportion of The buoyancy available, dP, is:the dilution air is drawn through the draught 6 x 0.43 = 2.58 mmwg diverters on atmospheric appliances. Ventilation requirements must take this into account and may Subtracting the loss from the buoyancy force:require larger louvres. P2 = dP -P1 = 2.58 -1.4816 = 1.0984 mmwg draught

THE ABOVE RECOMMENDATIONS ARE FOR GENERAL GUIDANCE ONLY. POTTERTON P2 is within the range 0 -4 mmwg and therefore is an acceptable draught. COMMERCIAL DIVISION CANNOT ACCEPT RESPONSIBILITY FOR FLUE SYSTEM DESIGNS Note: P2 is a negative pressure, ie. suction at the BASED ON THE ABOVE RECOMMENDATIONS. flue exit.
Difference between hot and cold running (p1 + P2):2.58 + 1.4816 = 4.0616 mmwg

This is less than 6 mmwg and therefore should give reliable cold start operation.

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALlATION, OPERATING & MAINTENANCE MANUAL

Section 3

Page 3.6

ARIZONA

Table 3.1a -Flue Resistance Losses Guide

FLUE DIAMETER (mm)

Arizona Model

200mm Flue Exit Loss mmwg 45 deg Straight Flue Bend Loss Flue Loss Gas per m Velocity mmwg mmwg m/s Flue Exit Loss mmwg

250mm 45 deg Straight Flue Bend Loss Flue Loss Gas per m Velocity mmwg mmwg m/s

Arizona Model

80 100 140 170 200 250 290 350 405

0.0909
0.1431 0.2823 0.4165 0.5893

0.0182
0.0286 0.0565 0.0833 0.1179

0.0152
0.0228 0.0413 0.058 0.0802

1.5042
1.8977 2.6652 3.2373 3.8932 0.1156 0.1706 0.2414 0.3766 0.5079 0.74 0.9905 0.0231 0.0341 0.0483 0.0753 0.1016 0.148 0.1981 0.0144 0.0203 0.028 0.0414 0.0537 0.0747 0.0964 1.7057 2.0718 2.4916 3.1123 3.6142 4.3626 5.0471

80 100 140 170 200 250 290 350 405

FLUE DIAMETER (mm)

Arizona Model

300mm Flue Exit Loss mmwg 45 deg Straight Flue Bend Loss Flue Loss Gas per m Velocity mmwg mmwg m/s Flue Exit Loss mmwg

350mm 45 deg Straight Flue Bend Loss Flue Loss Gas per m Velocity mmwg mmwg m/s

Arizona
Model

200 250 290 350 405 465 520 580 640 700 800

0.1164
0.1816 0.2449 0.3569 0.4777 0.6298 0.7874 0.9798 1.1904

0.0233
0.0363 0.049 0.0714 0.0955 0.126 0.1575 0.196 0.2381

0.0119
0.0175 0.0228 0.0316 0.0408 0.052 0.0632 0.0766 0.0908

1.73031
2.1613 2.5099 3.0296 3.505 4.0247 4.5 5.0198 5.5332 0.098 0.1322 0.1926 0.2578 0.34 0.425 0.5289 0.6426 0.7689 1.0054 0.0196 0.0264 0.0385 0.0516 0.068 0.085 0.1058 0.1285 0.1538 0.2011 0.0085 0.011 0.0153 0.0198 0.0252 0.0306 0.037 0.0439 0.0514 0.065 1.5879 1.844 2.2258 2.5751 2.9569 3.3062 3.688 4.0652 4.447 5.085

200 250 290 350 405 465

520
580 640

700
800

Section 3

Page 3.7

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA

Table 3.1 b -Flue Resistance Losses Guide

FLUE DIAMETER (mm)

Arizona Model

400mm Flue Exit Loss mmwg 0.1129 0.1511 0.1993 0.2491 0.31 0.3767 0.4507 0.5893 0.7453 1.1135 45 deg Straight Flue Bend Loss Flue Loss Gas per m Velocity mmwg 0.0226 0.0302 0.0399 0.0498 0.062 0.0753 0.0901 0.1179 0.1491 0.2227 mmwg 0.0082 0.0105 0.0134 0.0163 0.0198 0.0234 0.0274 0.0347 0.0426 0.0605 m/s 1.70421 1.9715 0.0944 2.2639 0.1244 2.5313 0.1555 2.8236 0.1935 3.1124 0.2351 3.4047 4.378 0.2814 0.4653 3.8932 0.3679 5.3513 0.6951 i 1.1268 Flue Exit Loss mmwg

Arizona Model 45 deg Straight Flue Bend Loss Flue Loss Gas per m Velocity mmwg 0.0189 0.0249 0.0311 0.0387 0.047 0.0563 0.0736 0.0931 0.139 0.2254 mmwg 0.006 0.0077 0.0094 0.0113 0.0134 0.0157 0.0199 0.0244 0.0347 0.053 m/s
350

450mm

350 405 465 520 580 640 700 800 900 1100 1400

1.5578 1.7887 2 2.231 2.4592 2.6902 3.0761 3.4592 4.2282 5.3832

405 465 520 580 640 700 800 900 1100 1400

FLUE DIAMETER (mm) Arizona Model


500mm

600mm

520 580 640 700 800 900 1100 1400 1650 1850 2100 2350

45 deg Straight Flue Flue Flue Straight Bend Loss Flue Loss Gas Exit Bend Loss Flue Loss Gas perm perm Velocity Loss Velocity m/s m/s mmwQ mmwg mmwg mmwg mmwp mmwg 1.62 0.102 0.0204 0.0057
45 deg

Flue Exit Loss

Arizona Model

0
520 580 640 700 800 900 1100

0.127 0.1543 0.1846 0.2414

0.0254 0.0309

0.0069 0.0082 0.0096 0.0121 0.0149 0.0211 0.0323 0.043

1.8071 1.9919 2.179 2.4916


0.089 0.1164

0.0369
0.0483 0.0611 0.0912 0.1479 0.2053

0.0178 0.0233 0.0294 0.044 0.0713 0.099 0.1245 0.1604 0.2008

0.0041 0.0051 0.0063 0.009 0.0137 0.0182 0.0223 0.0278 0.0338

1.5132 1.7303 1.9458 2.3784 3.028 3.5683 4.0009 4.5412 5.0816

0.3053
0.4561 0.7393 1.0266

2.8019 0.1472 3.4248 0.2199 4.3604 0.3565 5.1384 0.4951


0.6224 0.8019

1400
1650 1850 2100 2350

1.0041

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL ARIZONA

Section 3 Page 3.8

Table 3.2

-Flue

Dilution Systems

-Duct

Sizes & Fan Volumes

Output odel

Gross Input kW

Input Gas m3/h

Flue Volume

kW 80 100 140 170 200 250 290 350 405 465--~ 640 80 700 800 900 97 121 169 205 241 302 350 9 11 16 19 23 28 33 39 46
52 59 65

@ 1% CO2 m3/s

Duct Diameter mm 200 200 250 300 300 350 400 400 450 500 500 550 600 600 650 700 750 800 900

Velocity

"'U""
m 0.32 0.365 0.447

m/s
8.587 10.733 9.617 8.11

0.27 0.337 0.472 0.573 0.674 0.843 0.978 1.18 1.366 1.568 1.753 1.956 2.158 2.36 2.698 3.035 3.709 4.721 5.564 6.238 7.081 7.924

0.502
0.554 0.633 0.692 0.775 0.846 0.919 0.983 1.049 1.113 1.175 1.273 1.366 1.541 1.78 1.965 2.104 2.271 2.429

9.541
8.762 7.782 9.392 8.587 7.986 8.93 8.232 7.633 8.348 8.129 7.886 8.396

422 489

561 627 700 772 844 965

72 79 90 101 124
158

1,086 1,327 1,689 1,991 2,232 2,533 2,835

~~~ ~~
1,650 1,850 2,100 2,350

9.392
8.746 7.943 9.016 8.338

186
208 236

264

1,000 1,000 1,100

Flue gas volume at 1013.25 mbars and 15C. Typical diluted flue gas temperature above ambient.

is 14OC

Un-corrected chimney height from the Clean Air Act.

~
I

Section 3 Page 3.9

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL ARIZONA The maximum and minimum design pressures are 8 bar (272 ft.w.g.) and 2 bar (68 ft.w.g.). Care is needed in siting the pump relative to the cold feed and open vent connections. (NOTE: The above are not static pressures).
The boiler flow and return given in Table 1.4. connection sizes are

WATER CIRCULATION SYSTEM


The water circulation systems should be indirect and installed in accordance with the relevant parts of British Standards Codes of Practice CP342 and

BS 6644: 1991.
The maximum and minimum design temperature differential across the boiler should be 20C and 10C and the boiler should be prevented from operating with flow rates giving a temperature difference across the boiler greater than 25C based on the full boiler output. Boilers operating under constant flow conditions can be more accurately controlled and are not subject to excessive temperature stresses. The boiler must not be fired with less than the minimum flow.

It is recommended that the system is designed to give a constant boiler flow rate. For ful1her information on water circulation systems see Pottel1on Publication Technical Bulletin Number 1
Issue 2. a

Boiler Condensation
If the system water content is large, and the start up period before which the water return temperature attains the minimum operating temperature exceeds 20 minutes then consideration should be given to the fitting of a shunt pump or by-pass valve controlled by a pipe thermostat to raise the return water temperature to prevent formation of condensation within the boiler and flue system. It should be noted that shunt pumps should not be used to boost low water flow rates. See Potterton Publication Technical Bulletin Number 1 Issue 2 for further information. Q!bER PROTECTION The provision of pump overrun by a time delay relay or a thermostat situated in the flow pipe close to the boiler is essential to remove residual heat from the boiler, see Figure 6.4, page 6.4. The boiler and system suitable frost thermostats. should be protected by

On systems with variable flow rates due to flow reducing devices, ie. TRVs, zone valves, etc., or where the minimum heat demand, ie. summer domestic hot water load, does not achieve the minimum boiler flow rate then consideration shall be given to incorporating a primary loop system. For further information see Potterton Publication Technical Bulletin Number 1 Issue 2.
The flow rate and hydraulic resistance for an 11C boiler temperature rise are given in Table 1.4, alternatively, flow rates through boilers can be calculated from:-

FLOW (Iit/sec) =

kW (Boiler Cutout)

4.2 x Boiler Temp Rise C


The minimum design flow rate relates to a 20C boiler temperature rise and should not be misinterpreted as the system design temperature drop particularly where systems have been designed with stand-by capacity.

The hydraulic resistance of the boiler is proportional for flow rates equating to a boiler temperature rise of between 10C and 20C. The hydraulic resistance at 11C AT is given in Table 1.4, hydraulic resistance at alternative flow rates can be calculated from:-

Unions and isolating valves should be fitted to the flow and return manifolds so that the boiler can be isolated from the system if the need arises.

Strainers
Migrating sludge and debris will have a detrimental effect on the life and operation of the boiler and this must not occur. If all debris cannot be removed, strainers and/or other devices should be fitted. Consideration should be given to water treatment and inhibitors to maintain water quality. Migration of system debris or scaling of the waterways will impair the life expectancy of the boiler sections.

R =
2

R, X

.~112
~

AT2J

where:- R1 = Boiler Resistance with temp rise ~ T 1 R2 = Boiler Resistance with temp rise ~ T 2

~T 1 = 11C AT 2 = Alternative

System Fillina
Boiler Temperature Rise When filling the boiler system with water care should be taken that the water does not backwash

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

Section 3 Page 3.10

ARIZONA

system debris into the boiler via the flow connection by-passing any strainers that may have been fitted. It is essential that all systems are thoroughly flushed through with a flushing agent to remove all debris and scale prior to fitting the boilers. Cleaning systems with acidic de-scaling agents is not generally recommended as, if incorrectly used, the scale and deposits may continue to break up after the system has been flushed and the boiler

NOTE: These are absolute pressures not gauge pressures. For gauge pressure 1 bar must be subtracted.

installed.
Where the boiler is being installed as a replacement for an existing boiler it is recommended that where possible sections of the removed boiler are cut open and internally examined to determine the presence of scale or system debris to foresee and rectify any potential problems for the new boilers.

: A boiler system with a maximum operating temperature of 93C and allowing for a safety margin of 17C the temperature would be93C+17C=110C From the above the minimum Qauge pressure within the system should be 1.43 Dar -1 bar = 0.43 bar

COLD FEED SUPPL Y


A cold feed pipe should be provided and taken directly from a feed and expansion cistern which shall not supply water for any other purpose. It shall not be smaller than as specified in Table 1.4 and shall be connected to the boiler or boiler side of any valve on the return pipe. The cold feed pipe shall be situated within the building and shall be insulated along those parts of it's length where freezing conditions or condensation may be expected to occur. For multiple and modular boiler installations the cold feed connection shall be either to the common return pipe upstream of the individual boiler isolating valves or to each individual boiler return pipe downstream of the isolating valve. The cold feed to a multiple or modular boiler installation shall be provided with a lockable isolating valve and sized in accordance with Table

The fitting of strainers is strongly recommended.


The system should be checked to ensure that there is no raw water make-up. It is strongly recommended that a suitable water meter is fitted to the cold feed supply of the boiler system to monitor for unregulated water make-up. The quality of the water in both the heating system and the water supply should be checked to ensure that the hardness and salinity are not excessive. In the case of systems containing aluminium components the pH should be monitored to prevent corrosion. On systems where unregulated raw water make-up or system debris is known to exist but remedial action cannot be implemented then consideration should be given to installing a heat exchanger to isolate the boiler from the water system to protect the boiler otherwise premature failure may occur. A specialist water treatment company should be consulted if in doubt. Open Vented Systems

3.4.

Maximum Operatina Temperature


The maximum operating temperature of a system is dependent on the operating pressure. The minimum design operating pressure (not static) at any point of a system should be sufficient to prevent boiling within any part of the heating system and the boiler control thermostat should be set to provide a 17C safety margin below the saturated steam absolute pressure given in Table 3.3 corresponding to the minimum design operating pressure. For fur1her details see BS 6644: 1991

It:Xample

Section 3

Page3.11

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA CISTERN SIZING


The cistern should be sized to accommodate the water expansion in the system from QoC to the maximum operating temperature. Where the volume of the system is not known then it can be estimated at 12 litres per kW of design load. For systems with a maximum operating temperatures of up to 100C the water can expand by 4% (for systems up to 140C the expansion is 8%). Therefore assuming a system loading of 1000 kW, the approximate system volume is 1000 x 12 litres = 12000 litres and the expansion of water in a system with a maximum design 100C is 4% x 12000 = 480 litres. temperature of venting point. The open vent pipe shall discharge into the feed and expansion cistern above the overflow level and for a single boiler installation the pipe shall not be fitted with valves (apart from a 3-way type such that when closed the boiler is open to atmosphere through the third port and shall incorporate means of indicating the position of the open port. The nominal bore of the valve shall be not less than that of the open vent pipe in which it is fitted). Nor shall there be any obstruction which could prevent safe venting of the boiler. The vent pipe shall be insulated along those parts of it's length where freezing may be expected and shall be situated as far as is practicab1e inside the building to reduce freezing problems.

In this instance the cistern should expansion capacity between the cold fill the overflow pipe of 480 litres (minimum), should be 80mm above the highest

have an level and (overflow expansion

Boiler Safety Valves

level).

Each boiler, whether in single or multiple installations, shall be fitted with an individual safety valve complying with BS 6759 Part 1.

IMPORTANT: The water level in the cistern or In the case of modular boiler installations each bank expansion tank should be minimal on cold of boilers shall be provided with a common safety charge to allow expansion without discharge valve sized in accordance Table 3.6 to suit the total from the overflow between cold and hot rated output of the boiler bank. Any boiler in a modular installation that can be isolated from the operating conditions.
water supply shall be fitted with an individual safety valve.

The safety valve shall be sized to suit the total rated output of the boiler and shall be located between the boiler and the water isolating valve. See Table 3.6 for safety valve sizes on open vented systems. Refer to notes on sealed systems for safety valve sizes on sealed systems.
The safety valves shall be fitted in the flow pipework between the boiler and the next valve in line and the safety valves shall not be more than 1 m from the boiler measured along the flow pipe. Boiler safety valves shall be of the direct spring loaded type or dead weight type and the maximum setting shall not exceed the following equation:-

MAXIMUM VALVE = 0.1 + MAX BOILER DESIGN SETTING (IN BAR) PRESSURE (IN BAR)
Multiple or modular boiler installations shall have an open vent pipe or pipes of the size stated in Table 3.5 as appropriate. Individual open vent pipes shall be either routed independently to the venting point or be connected to a common open vent pipe of appropriate size for the total rated heat input of the installation (see Table 1.4 for individual boiler open vent sizes). The open vent pipe shall rise continuously by the shortest practical route to the NB: 1 Bar = 33.5 ft head or 14.5 Ib/in2 On systems containing components with lower maximum operating pressures than the boiler, the rating of the safety valve should be reduced accordingly or additional safety valves provided to protect these items.

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA

Section 3 Page 3.12

without exceeding the maximum design pressure of the boiler.

The position of the expansion vessel(s) should be such that the manufacturers maximum operating temperature is not exceeded and the provision of an anti gravity tank may be required for systems operating above 100C.
In addition, the position of the expansion vessel(s) should prevent inadvertent isolation of the boiler system from the expansion vessel, where isolating devices, ie, valves, etc., are incorporated between the boiler(s) and the expansion vessel these should be capable of being locked in the open position during normal operation. See BS 6880 Part 2 for further details. System Fillina & Water Make-Uo The sealed system should incorporate suitable means for initial filling, ie. pressure boost pump, which shall comply with the local water authority bye laws and the cold feed supply to the system should incorporate a non-return valve and an isolating valve with the capability of being locked in the open position during normal operation. An automatic air vent should be provided between the isolating valve and the non-return valve and provision should be made within the sealed system to allow automatic replacement of water lost from the system. This may include a pressure boost pump and associated controls or an independent primary feed cistern. However, it is recommended that a suitable device such as a water meter is installed to detect unregulated raw water make-up. See BS 6644: 1991 for further details on provision for filling and make-up on sealed systems. Maximum ODeratino Temcerature The maximum operating temperature of a sealed system is dependent on the operating pressure. The minimum design operating pressure (not static) at any point of a sealed system should be sufficient to prevent boiling within the any part of the heating system and the boiler control thennostat should be set to provide a 17C safety margin below the absolute saturated steam pressure given in Table 3.3 corresponding to the minimum design operating

"A" can be calculated from:A= R 0.659 x P1 x I!cdr where R = boiler output in kW, P1 = 7.6 Kdr = The de-rated coefficient of discharge, (available from the safety valve manufacturer) and A = flow area in mm2

Alternatively

Spring loaded valves are recommended where the static head exceeds 2.5 bar and/or where the boiler may be affected by external vibrations.
The size of the connecting pipe from the safety valve shall terminate in a visible position where discharge will not result in hazard to the user or plant. The size of the discharge pipe shall be not less than the nominal size of the valve outlet. For fur1her guidance on safety valve sizes see BS

6644: 1991.

SEALED SYSTEMS

General
Potterton Commercial boilers are suitable for use on sealed systems designed in accordance with BS 6644: 1991 and BS 6880 Part 2. In addition, reference should be made to the Health & Safety Executive guidance note PM5 "Automatically Controlled Steam & Hot Water Boilers".

Expansion Vessels
The sealed system should incorporate an expansion vessel complying with BS 4814 sized to accommodate the volumetric hydraulic expansion of the heating system between ooG and the temperature setting of the overheat thermostat

pressure.
The boiler overheat thermostat should provide a safety margin of at least 6C below the absolute saturated steam pressure.

Section 3 Page 3.13

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA
Minimum Operating Pressure The minimum operating pressure (not static) or cold fill pressure should be sufficient to maintain a positive pressure within the heating system to prevent boiling as detailed above. Care should be taken in positioning of the circulating pump(s) relative to the expansion vessel (zero or null point) particularly on systems where a high hydraulic resistance is present to ensure that operation of the pump does not cause a reduction in operating pressure at any point in the system below the minimum operating pressure. A low water pressure cut off device shall be incorporated to prevent operation of the boiler plant on low water pressure. The pressure cut off device should be set at a pressure to prevent boiling in any part of the heating system while operating at the design working temperature.

Consideration should be given to the positioning of safety valves, low level cut off devices and automatic air vents relative to the minimum operating pressure to ensure that the influence of pump operation does not cause or prevent operation of these devices.

Maximum Ooeratina Pressure The boiler plant should be prevented from operating when the system pressure rises to within 0.35 bar of the safety valve setting. .

Safetv Valves The safety valve on a sealed system should be sized in accordance with the following equation. A = R 2.5 x Kdr

where R = Kdr=
A =

Boiler output in kW the de-rated coefficient of discharge (available from the safety valve manufacturer). flow area in mm2

NOISE LEVEL
Detailed figures are available on request for all types of burner specified with the Arizona boiler. Additionally gas boosters may be required for some burners, especially with the larger Arizona boilers.

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

Section 4 Page 4.1

ARIZONA BOilER INSTALLATION


Table 4.1 -Number Boiler assembly and installation out by a competent person. should be carried , Model of Turbulators

The boiler shell is supplied complete with the combustion chamber door fitted. Once placed in it's final position, (for site and base requirements see page 2.2), complete the installation of the Arizona boiler as follows. Ensure that the boiler is installed stable. level and

No. of Flueway tubes

No. of
Turbulators 0 4 12 32* 21 21 16 22 26 30* 19 25 28 32* 32 32 56 45 59 61 92 100

80 100 140 170 200 250 290 350 405 465 520 580 640
700

12
12

18 18 21 21
22 22 26 26 25 25 28 28 32 46 56
64

2.

Open the combustion chamber door and remove the boiler control panel and fittings pack from within the combustion chamber.
Ensure that nothing is left in the combustion chamber then close the combustion chamber door, (note that the combustion chamber door needs to be re-opened -see below). Fix the burner adapter plate to the combustion chamber door, using the gasket supplied. Fit the burner gasket and mount the burner on to the boiler and secure. Re-open the combustion chamber door and fill the gap between the burner blast tube and the combustion chamber door insulation with the ceramic fibre roll provided. Push it into place 50 that it is flush with the combustion chamber door insulation.

3.

4.
5

800 900

1,100
1,400 1,650 1,850

6.

84 88 65 70

2,100 2,350

Figure 4.1 -Boiler combustion chamber door

Two turbulators installed in each flueway tube. Turbulators Turbulators are fitted to all boiler models to improve efficiency. Turbulators will be fitted to between 70% and 100% of boiler flueway tubes depending on the model of boiler, see table 4.1 for details of the number of turbulators. Turbulators should be installed evenly from the top of the boiler. Where boilers have flueways without turbulators these flueways should be at the bottom of the boiler.

8.

7.

Check that the correct number of turbulators are fitled into the flue way tubes, see table 4.1 and that they are located correctly, see figure 4.2. Ensure the turbulators are pushed fully into the flue way tubes as far as they will go.

Ensure that the combustion chamber door seal is intact and correctly located then close the combustion chamber door and secure.

9.

Fit the loose supplied blanket insulation around the front of the cylindrical boiler heat exchanger,

Section 4

Page4.2

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL ARIZONA 16. Connect the burner via the 2 Weiland plug connectors provided. (Note: If a 3 phase burner is fitted a separate 3 phase electrical supply must be provided via a fused isolator to the burner motor contactor). See wiring diagram section 6 page 6. 1.
17. Locate the side casing panel in the lower casing support rail. Lift the top chequer plate slightly to allow the side panel to be positioned underneath the lip of the chequer plate thus holding it in place. Repeat with the other side casing panel. Panel Mounting

tucking the edges underneath to secure, see figure 4.13. .

10. Fit the control panel support bracket, see


figure 4.3.

11

Remove the rear cover from the control panel and fit the control panel to the control panel support bracket. see figure 4.3. (See additional information on control panel page

4.5).
12. Thread the thermostat and thermometer capillaries through the access hole in the boiler top and fit phials into the phial pocket at the base of the flow outlet pipe. See figure

Fiaure 4.3 -Control

4.4.
13. Fit the burner cable support brackets to the front vertical casing support rail, see figure 4.7 14. Fit the burner cable conduit to the control panel and wire to the control panel tenninal block, see wiring diagram page 6.1. 15. Secure the burner cable conduit to the front casing support rail, see figure 4.7.

Fiaure 4.4 -Phial Pocket Location

F~~r~ 4,6 -Installation of Turbulators and Location


of Boiler Control Panel

0
BURNER REQUIREMENTS
The Arizona boiler supplied with a matched oil or gas burner to Potterton Commercial specification. If any other burner equipment is to be used ensure that it is suitably matched to operate with the boiler. Also ensure that the burner tube is of the correct length as per figure 4.5 and table 4.2. Note that the Arizona has a reverse flame combustion chamber and the products of combustion may short circuit if the minimum burner tube lengths are not adhered to.

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

Section 4 Page 4.3

ARIZONA Fiaure 4.5 -Burner tube installation

Table 4.2 -Minimum burner tube lenath Boiler Model Combustion chamber door burner orifice diameter D mm
220 220 220 220 220 270 270 270 270 270 270 270 270 270 270 270 270 270 270 350 350 420 Burner tube

minimum length Lmm


180 180 180 180 180 180 250 250 250 250 250 250 250 250 310 310 310 310 310

80 100 140

170
200 250 290 350 405

BurnerAdapterPlate
A burner adapter plate is supplied with each boiler specific to the burner to be used. If a burner other than a Potterton specified burner is to be used a blank burner adaptor plate will be provided for drilling by others. .

465 520 580 640 700 800 900

WATER CONNECTIONS Connect the boiler to the circulating system. Connection sizes are given in table 1.4. The orientation of the connections, flow and return, is given in figure 1.1. A drain connection is provided at the rear of boiler.

1,100 1,400
1,650 1,850

2,100 2,350

BOilER

& BURNER POWER SUPPLY

Burner Cables The Arizona boiler is supplied as standard fitted with two burner control cables, a 7-pin Weiland plug and a 4-pin Weiland plug, from the boiler control panel for connection to the burner. In addition for gas burners the burner controller must be connected to the gas train -See the burner manufacturers instructions for details.

The Arizona boiler is supplied with either a single phase or a three phase burners. Check the burner data plate to identify the power requirements.

General ReQuirements
All electrical connections to the boiler and burner should be made via a fused isolator which should be positioned adjacent to the boiler. The isolator should isolate all power supplies to the boiler including control signals if applicable. See figure

Hiah/Low Burner
The 7-pin and 4-pin Weiland plugs should be connected to the respective sockets provided on the burner. On/Off Burner The 7-pin Weiland plug should be connected to the respective socket provided on the burner. The 4-pin plug should be disconnected from the control panel and discarded, see wiring diagram page 6.1.

4.6.
The control panel incorporates a 6.3A fuse

8)

Section 4 Page 4.4

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA
FiQure 4.6 -Boiler & Burner Power SUDDlv

SinQle Phase Installation 3 -Phase Applicable to the smaller typically Models 80 to 290. boilers , in the range, Applicable to the larger boilers in the range, typically Model 290 and above. Install a 400V 50Hz 3-phase electrical supply to the burner motor contactor as per the burner manufacturers instructions and, install a single phase 230V 50Hz electrical supply derived from the 3-phase supply to the boiler control panel. Installation Install a 230V 50Hz single phase electrical supply to the boiler control panel. No separate electrical supply to the burner is required. The burner is powered from the control panel lead. Burners requiring start or run current 6.3A should not be used. exceeding

FiQure 4.7 -Burner

Cable Conduit FixinQ

Fiaure 4.8 -Boiler Control Panel Wilina Connections


BlankplaJe

u
~

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL ARIZONA

Section 4
Page 4.5

PANEL
The Arizona has a comprehensive control with the following functions:."..v Overheat thermostat Low fire thermostat (2nd stage) High fire thermostat (1st stage) 1 st stage hours run meter 2nd stage hours run meter Boiler thermometer Indicator lights Plus, as an optional extra, facility for remote signalling of boiler fault, overheat and burner lockout and, boiler run 1st and 2nd stage. panel

~
1.

2. 3.

4.
5. 6.
78.
7b

8.
9. 108. 10b. 118. 11b. 12.

13.

Power on light (Orange) Pump on/off switch Burner on/off switch Overheat thermostat test switch 6.3A fuse Boiler thermometer 1 st stage hours run meter 2nd stage hours run meter Burner lockout indication light (Red) Blank cover -optional controller fixing point 1 st stage control thermostat 2nd stage control thermostat 1 st stage run indicator light (Green) 2nd stage run indicator light (Green) Overheat indicator light (red) Overheat thermostat re-set button

1. Open the wired control panel package. 2 Remove the transparent plastic instrument
panel dust cover from the control panel body lifting it horizontally. Remove the control panel top cover, see figure 4.10. Turn the control panel over to provide access to the cable outlet. Insert the capillaries and earth wire into the rectangular cut-out in the front top and then below the front cross bar. Fit the burner cable conduit elbow into the hole provided on the control panel. Wire the burner cables to the control panel terminal block as per figure 6.4.

8.

3 4

9. 10.

11. 12. 13. 14.

6 7

Position the control panel on the control panel mounting plate and fix the control panel to the boiler. Connect the earth wire onto mounting nut to earth the control panel to the boiler body. Thread the capillary tubes through the hole in the boiler chequer plate top and locate them in the phial pocket on the flow pipe header. Ensure they are pushed fully home. Connect the control panel to the power supply as shown in figure 4.6. Make any control connections as required. Refit the control panel top and transparent dust cover. Connect burner cable plugs to the sockets provided on the burner.

.~~;L~TROL
5.

Section 4 Page 4.6

POTTERTON COMMERCIAL PRODUCTS INSTALLATION, OPERATING & MAINTENANCE

DIVISION MANUAL

ARIZONA Fiaure 4.10 -Control Panel Assemblv

110.
Front

Fiaure 4.11 -Hours

Run Meter AssemblY

OPTIONAL CONTROLLERS Optional controllers are available for the Arizona boiler to provide a complete system control package. Refer to Potterton Commercial Technical department for controller availability and function.

=//ighl

Wann rng

Black wires

Blue wires

Controller Installation to the Control Panel Controllers are delivered mounted on a printed circuit board. To install the controller to the Arizona instrument panel proceed as follows:1. Unclip and remove the instrument panel fascia cover. Remove the top cover of the instrument panel (three screws). Undo two screws holding the instrument panel fascia in place and drop the instrument fascia forward. Remove the blank plate in the fascia covering controller position. Fit the controller into the prepared fixings (five off) in the instrument panel and bolt tight to secure, see figure 4. . Feed any capillaries through the instrument panel grommet to the sensor pockets. Connect all sensor and control system wiring. IMPORTANT: Do not install sensor cable and 230V cable in the same conduit. Disconnect the twelve way connector, (boiler control wires), and connect to then controller printed circuit board. Replace instrument fascia panel, top and fascia cover.

"'"
Fiaure 4.12 -Installation

2.
HOlrS run meter

3. Remove the spade connector covers from the boiler run indicator lights and connect the hours run meter in parallel to the light.

4. 5.

of Controller

6. 7.

8.

9.

.
~

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL ARIZONA

Section 4 Page 4.7

Fiaure4.1 ;:allation

:;:at

Exchanaer Blanket

Cut the insulation blanket to the correct length and ensure it is not pinched tight when tightening the blanket in place. Ensure that the blanket butts up to the front and rear of the heat exchanger.

INCORRECT

CORRECT

2.

Do not overlap the insulation blankets.

For a correct fit the blankets should butt together.

INCORRECT

CORRECT

3. When fitting the insulation blanket ensure that the blankets fit togther in the correct way to minimise heat loss from the heat exchanger.

INCORRECT

CORRECT

.,

Section 5 Page 5.1

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA
BOilER COMMISSIONING
Water Quality 1. It is important for the longevity of the boiler shell that water of the appropriate quality is used in the system to avoid the formation of limescale in the boiler. Note the fill water requirements page 2.2. stated in Section 2 4. Where the water volume of the heating system is large and the water is very hard the fill water should be softened. 2. Electrical supply is of the correct voltage and polarity and earthing is available. The fuel supply is of the correct type for the burner fitted, tested for soundness, purged of air and correctly connected to the burner. Boiler and system are fully flooded with water and the water system operating pressure is within the boiler range. Pumps are operational and any flow proving interlocks are functional. The operation of the pump should be checked, particularly on sealed systems, to ensure that the operation does not cause a reduction in pressure within the system below the minimum operating pressure. ventilation is adequate and in the case of mechanical ventilation systems, operation of the boiler is inhibited unless the ventilation fan is proved. On mechanically assisted flue systems the operation of the boiler plant should be inhibited unless the mechanical flue system is operational and flow proved. The safety valve should be checked to ensure that it is of the correct size and pressure. See section 3 for further details. The cold feed and open vent sizes should be checked. See section 3 for further details. Ensure the burner fitted to the boiler is of the correct specification and size for the boiler and suitable for the fuel supply available. The burner blast tube has been sealed to the door refractory and the boiler door seal is correct. See section 4 for further details. Before commencing check the following:commissioning the burner

1
;c. "-

" ~

3.

WARNING: After initial filling under no circumstances should unregulated make up water be introduced into the system. If a water leak is detected in the system it should be repaired immediately.
In the event of limescale or water corrosion causing the failure of the boiler shell the boiler warranty is invalidated. It is recommended that a water meter is fitted to and the amount of raw make up water monitored.

5.

~ v "

6.

7.

8. Safety Interlocks The operation of safety interlocks such as water flow proving, gas boosters, mechanical ventilation, 9.

mechanical flue systems should be checked to


ensure that operation their failure. of the boiler is inhibited on

10.

BURNER COMMISSIONtNG

Comoetency
IMPORTANT: The boiler must be commissioned following completion of installation. Operation of an un-commissioned appliance is a criminal offence. It may cause injury to personnel and damage to the boiler and will invalidate the boiler warranty. Commissioning should only be carried out by personnel approved and competent to do so. This facility is available from Pottel1on Commercial Service Offices at the addresses listed on the back of this manual.

Following completion of the above checks the burner should be commissioned in accordance with Ii; the manufacturers hand book provided with the. burner. The commissioning form provided at the back of this manual must be completed and returned to Potterton Commercial at the address on the back page.
Typical combustion figures are:CO2 Gas 9-10% Oil 12-13% CO 0-20 ppm Oil Firing Smoke No. 0-1 (Bacharah Scale) Flue Gas Temperature section 1 page 1.3. ~ see Technical data in

Commissioning of the burner should be carried out in accordance with the burner manufacturers instructions provided.

IMPORTANT: A condition of the supply of the appliance for compliance with the Potterton Commercial Quality Assurance, (registered to meet the requirements of BS5750 Part 2), plan is the return of the appliance commissioning report, enclosed at the back of this manual.

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

Section 5

Page 5.2

ARIZONA

Following/during commissioning of the burner unit the following additional checks should be carried out.
1. Operation of the overheat thermostat. This can be tested using the overheat thermostat test button on the boiler control panel. Operation of the control and high/low (if fitted). thermostats. (1 st and 2nd stage thermostats). should be checked. The flue draught available at the appliance flue outlet should be checked under all operating conditions (hot and cold) and should be within the boiler operating parameters, see table 1.4. The fuel supply to the appliance should be isolated and the burner operated to ensure safety shutdown and lockout of the bumer on flame failure. Shutdown of the boiler plant by external controls does not cause a hazardous condition and pump overrun is provided to remove residual heat from the boiler. Following commissioning the boiler overheat and control thermostats should be set to the required operating setting. See section 3 for maximum operating temperatures. Following completion of commissioning the soundness of all automatic fuel valves should be checked for leakage.
I

Where overheat operation is reported the following should be checked. (a) The boiler/system pump is adequate for the duty. (b) Operation of flow reducing devices, i.e. thermostatic radiator valves, compensated mixing valves, etc., do not reduce the water flow rate through the boiler below the minimum flow rate. See Water Circulation Systems, section 3 for water flow rates. (c) Pump overrun is incorporated to dissipate residual heat from the boiler on system shut down. (d) The operation of boiler back-end valves incorporate a time delay to allow for removal of residual heat from the boiler. (e) The boiler is operating at the correct rate and is not over-fired. The use of as primary loop system is highly recommended to provide constant boiler flow rate under all operating conditions. For further information refer to Potterton publication Technical Bulletin No.1, Issue Water Circulation Systems.

2.

3.

4.

5.

6.

7.

Burner Lockout
The package burners supplied with the boiler unit have an integral safety system to allow the safe and reliable operation of the burner. Failure of the burner to operate correctly will cause the burner control box to "lockout", the lockout button on the burner will illuminate to indicate this. The lockout condition can be manually reset by pushing the reset button and the control box should restart it's control sequence in an attempt to light the burner. If the control box lockout will not reset or goes to lockout after being reset then the services of a boiler repaor/maintenance company should be sought. This service is available from Potterton Commercial Division Service at the addresses on the back page of this manual.

Additional Checks Where possible the system should be checked to ensure that following purging of air there us no raw water make-up. In particular, when the system us operated in the hot condition, there should be no discharge of water from the safety valve, open vent or cold feed tank overflow that would otherwise lead to unregulated raw water make-up when the system cools down.

FAULT FINDING
General fault finding for burner failure should be in accordance with the burner manufacturers hand book. Set out below are general guidance notes on system fault finding.

WARNING: The lockout reset button should not be repeatedly operated otherwise a hazardous situation may occur.
Should the boiler go to lockout, check the following before attempting to re-light the burner. 1. Fuel is available at the burner. 2. The electrical supply to the appliance is of the correct voltage and polarity. The boiler control boxes in some instances have indicator dials as an aid to fault finding on boiler lockout. In these instances refer to the control box manufacturers data sheet for fault finding details.

Overheat Operation
The boiler control panel has an built in overheat indicator lamp. Operation of the boiler overheat thermostat is associated with a reduction in boiler water flow. The overheat thermostat can be tested by pressing the test button on the boiler control panel. Note that the boiler temperature will rise to

110C.

Section 5 Page 5.3

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALlATION, OPERATING & MAINTENANCE MANUAL ARIZONA 2. Brush out the flueway tubes ensuring any soot is removed. 3. Re-commission the burner as per the burner manufacturers instructions and instructions given on page 5.1. Lenathv Shutdown
If the boiler is left shut down for a long period of time consideration should be given to placing a box containing quicklime in the combustion chamber to prevent moisture building up in the boiler. Boiler Checks -Combustion Chamber

BOILER MAINTENANCE
It is essential for efficient and trouble free operation that the boiler plant is regularly maintained. This must be carried out by qualified and experienced engineers and in the case of gas fired appliances attention is drawn to the requirement that ACOPS certified engineers only undertake this work. Potterton Commercial Service Division provides a full maintenance service -see the back of this installation manual for the telephone number of your local service depot. Service Interval The Arizona boiler and burner should be serviced and the burner re-commissioned once per year.

In addition to the checks on the water system the combustion side of the boiler should be maintained as follows.

WARNING: Isolate the electricity and fuel supplies to the boiler before commencing any maintenance work.
Boiler Checks -Water System

Natural Gas & LPG Fired Boilers The combustion chamber and flueways should be brushed out and any debris removed from the boiler bi-annually.
Class "0" Fuel Oil The boilers should be brushed out thoroughly at least bi-monthly during the heating season but more frequent attention may be necessary dependent on the operating conditions to prevent the formation of hard adherent scale on the tube surfaces. It is essential to ensure that cleaning is carried out throughout the full length of the flue tube passes and that the rear clean out covers are taken off to allow for the removal of deposits brushed through into the flue box. Should heavy or tough adherent deposit become formed, which is too hard for the standard brush to remove, it may be necessary to :Wash out the tubes with water followed by a thorough brushing -this may have to be repeated several times

Weekl~ -Check the amount of raw water make up. If raw water make up is occurring IMMEDIATELY identify and rectify any leaks on the system. Monthl~ -Check to make sure there is no sludge in the boiler by isolating the boiler and draining down. Quarterly -Shut down the boiler, open the combustion chamber door and check that the refractory is in good condition and that the flueways are not blocked, (i.e. clogged with soot). Withdraw and visually check the turbulators for soot and deterioration. Take a sample of system water and analyse for:pH value Hardness Oxygen Steel content Copper content If the water analysis exceeds the maximum recommended concentration levels then remedial action should be taken to treat the water see section 2 page 2.2 for details.

or,
.Use a flexible drive rotary descaling machine. The Arizona boiler should not be fuelled by medium or heavy fuel oil.

Annual Service At the annual service carry out all the operations for weekly, monthly and quarterly maintenance and in addition:-

Comoletion of Maintenance
On completion of annual maintenance and when the boiler combustion chamber door has been opened the boiler should be re-commissioned as described on page 5.1 above.

Open the combustion chamber door. Check the condition of the turbulators by removing them from the flueway tubes.

""" 6

Wirina Diagram

Section 6

Page 6.2 ARIZONA

..c

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(,)

it::

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.cU-2> 3: :1:-9 (/) C


'-

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-tU:;:; tU-(,)

<I> -C -(,)0 <I>

~
,-~o

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0(,)..c..Q~

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mO.-IJ J mO.I-\-"

N I 'DO

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cuO>O>o_cu G)cucul-I-G)

.-

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-;=..-

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O"-NQ.mO
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OOu-a-1-1-

"'-N

r r1 ~
~
,~ B ~

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL ARIZONA

Section 6 Page 6.3

Control Panel Wirina


The Arizona boiler can be connected to a Building Management System

The following remote signal options are available.

1
2

Burner lockout alann signal 1 st stage boiler run indication


Free Contact Connections IG~IEINIJ

3,

4.

2nd stage boiler run indication Boiler overheat alarm signal

Fiaure 6.3 -Volt

I~I~L

Control Panel terminal block

,<,
\(

vsc

CH2

~
VOLT FREE CONTACTS
R1 R2 R3 R4 -BURNER LOCKOUT INDICATION -1ST STAGE RUN INDICATION -2ND STAGE RUN INDICATION -OVERHEAT INDICATION

[r:r;! r:;! r:;! [I ~t;;T, ~

It is also possible to fit a local/remote switch. This is fitted by utilising the heating pump switch fitted to the control panel. The local/remote overrides the boiler external on/off control, (X1) and external high/low control (X5).

Fiaure 6.4 -Octional

Local/Remote

Switch Wirina

'} R21 .

Section 6

Page6.4

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA
Fiaure 6.5 -Pumc Overrun Usina Chanaeover Pice Thermostat

INCOMING SUPPLY FROM FUSED ISOLATOR

RELAY

NC

PIPE THERMOSTAT

PUMP

SET <55 DEG C

Pump overrun equipment is not supplied by Potterton

Fiaure 6.6 -Burner Connection Wirina

7-PIN PLUG ON/OFF OPERATION

L
N E T1

-PERMANENT BURNER LIVETO

-NEUTRAL -EARTH -CONTROL CIRCUIT TO BOILER CONTROL PANEL T2 -ON/OFF CONTROL CIRCUIT

TO BURNER
S3 -LOCKOUT SIGNAL 84 -BOILER RUN SIGNAL
4-PIN T6 B5 PLUG -HIGH HIGH/LOW FIRE OPERATION SIGNAL;

CONTROL RUNS-IGNAL-

FROM T7 T8 -NOT -HIGH TO

BURNER USED FIRE CONTROL SIGNAL

BURNER

7 -P1N W~llANQ P,LUG

4-PIN WEILAND PLUG

Section 7

Page 7.2

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA

Boiler

Component

Parts List

~
01 02 03

DESCRIPTION
FRONT SIDE PANEL (2-0FF PER BOILER) REAR SIDE PANEL (2-0FF PER BOILER) INSULATION BLANKET (2-0FF PER BOILER) (Not shown) CONTROL PANEL MOUNTING BRACKET CONTROL PANEL MOUNTING PLATE FIXINGS STEEL CHEQUER PLATE TOP (LEFT HAND SIDE) STEEL CHEQUER PLATE TOP (RIGHT HAND SIDE) COMBUSTION CHAMBER DOOR COMBUSTION CHAMBER DOOR HINGE COMBUSTION CHAMBER DOOR HINGE PIN COMBUSTION CHAMBER DOOR HINGE PIN NUT COMBUSTION CHAMBER DOOR INSULATION COMBUSTION CHAMBER DOOR SEAL EYE GLASS ASSEMBLY COMBUSTION CHAMBER DOOR FIXING BOLTS BURNER ADAPTOR PLATE (SOLID) (requires drilling to suit burner specification) BURNER ADAPTOR PLATE GASKET BURNER ADAPTOR PLATE FIXINGS COMBUSTION CHAMBER DOOR SEAL

PART No

04
05 06 07 08 09

10 11 12 13 14 15 16
17
18 19 20

()

TURBULATOR
(See page 4.1 for No required per boiler) CERAMIC FIBRE BURNER TUBE INSULATION (Not shown) SMOKE BOX CLEAN OUT ACCESS PLATE (Not shown) SMOKE BOX CLEAN OUT ACCESS PLATE FIXINGS (Not shown) TWO PART BOILER FLUE CLEANING BRUSH (Not shown)

21 22 23
24

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL ARIZONA

Section 7
Page 7.3

Fiaure 7.2 -Control

Panel Comoonents

101

117 114

133

-",.

;.

~"

/l
,,

0,"I "
f

'~,

~~ "
"
,
~~';.<~. ? "ti}) ',~
~/

/'10
I<"'-,..~

I ~" , " '~< t'..J ~ ,~

.'J ~. ~ ~ '"," ,,~

~ ~, '~'J"

~ ~~ ':--~ ~ ~ "

~--<,

~-

'""""'" ~

119'--

111

'- ',j;i I,

, ~ .

Section 7

Page

7.4

POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA
Control Panel Parts List

1IgM
100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 133 134

Qfj3CRIPTIOtj

PART No
17202471 17003854 17005591 15838260 15838262 15838261 15803999 15803525 15804020 15804082 17006994 17004739 17006940 17002268 17007061 17002281

TRANSPARENT INSTRUMENT SCREEN


CONTROLLER BACK PLATE (BLACK) ALARM INDICATOR LIGHT (RED) RUN INDICATOR LIGHT (GREEN) 0=12 POWER ON INDICATOR LIGHT (ORANGE) LS 5A B5 0=12 FUSE HOUSING 6.3A FUSE PUMP ON/OFF SWITCH ~~ooB5 NN TWIN SWITCH (BURNER ON/OFF / OVERHEAT TEST) CONTROL THERMOSTAT RAK 51.41.71 THE:RMOSTAT KNOB (MOD 91) OVI::RHEAT THERMOSTAT SECU. RAK 67.44.71 BLANK PLATE (BLACK) NXR1 THERMOMETER RECT 200C -120C THE:RMOMETER BLANK PLATE HOIJRS RUN METER BURNER CABLE 1ST STAGE (7 PIN WEILAND PLUG) BURNER CABLE 2ND STAGE (4 PIN WEILAND PLUG) COrllNECTOR T/B COrllNECTOR G15 & G25 SIDE PANEL RIGHT SIDE PANEL LEFT MISC. FIXING PACK L PANEL

17001213 17077185 17077186 17070758 17070759 17002287 17002289 17880347

Brooks House. Coventry Road, 'fIarwick Warwickshire CV34 4LL. Tel: (08706) 050607 Fax: (08706) 001516

4.9I PR 4.1J Is the boiler house ventilation as per manual?

4.~J..ElectriC supp~sed, RHI


I Class 0 I LHj Centre I

isolated & earth wire connected?

4..~.1Check external controls allow o~~~_tion

4.4
i N/Gasl LPG!

Check boiler/system flooded & pumps operational and any isolation valves open

6UBN~R
Type
Serial No

Coco

i4,~.j Check gas available at burner


4..51J) Check oil available at burner 4.6~1 Check gas meter sizing adequate

2.3

4.1 j Check flues~stem clear


Spec No

ControlBox Type
Electrical Supply Gas Train Type & Size Gas Train Serial No Gas Booster Type & Size

'5.0
5.1.*

t.CQ~aytION
Pilot I Low I High I
1Gas rate

Unit m3/hr

5,2" 1Burner head pressure


5..$* j lonisation probe/UVcell 5..41 Air shutter position 5.511 I Oil pump pressure current

mmwg uA

2.9" Gas Booster Serial No


3;1
mm mm mm mm
Side No of Holes

5,f} .! CO2 or 0,

1%

5.~J co
5.81/ I Smoke Number

5.9) Grossfluegas te~~~~


5..10i Ambient temperature 5,11 J Flue draught installation, inlet gas pressure all boilers high fire I .1..5...131 Combustion chamber resistance 5.14J Burner fan static pressure

c
'C mmwg mmwg

Diameter End 3.51' Oil Nozzles: High Fire Low Fire


No of Holes

Imm

5.12* Inlet gas pressure (high fire). If multi boiler

Di Si Ty Si Ty

Imm

mmwg
mmwg

MQI.E: Normally 5.13 and 5.14 only recorded when tappings provided. Position of measurement to be in accordance with boiler I burner manufacturers instructions.

3.6 Electrode Settings?


(to burner card/manufacturers instructions)
Burner to Spec?I (to burner card/manufacturers instructions)

.
11

GAS FIRED INSTALLATIONS ONLY Oil FIRED INSTALLATIONS ONLY

~
~
I 3.5.1 13.7 ~

17.17~Vidence

of condensate formation?

YES I NO

7.18 Any evidence of water leakage?


~~ 7.19 Any evidence of flue gas leakage?

YES I NO YES I NO YES I NO

1.20 Has boiler been built and cased correctly'? 7.21* 7.2 Is oil filter fitted? s fire valve fitted? il Supply: YES I NO YES I NO Single pipe

I Document ID Ref: PCF/O29~

~O
J

CONVERSION TABL~, IMPERIAL TO METRIC I~ I METRIC TO IMPERIA

I tlMI 1 Btu/hr 1 Btu/hr 1 Btu/hr 1 ft3

1 Therm = 100.000 Btu/hr = 0.2931 W = 1055 J = 0.252 kcal =


28.317 dm3 0.02832 m3 4.546 litre 1.2 U.S. Gallon

1 kW 1 J 1 kcal

3412 Btu/hr 0.0009478 Btu/hr 3.968 Btu/hr

1 dm3 = 1 LITRE
1 ft3 =I 1 Imp. Gall = 1 Imp. Gall = 1 m3

1,000 dm3 = 1m3


35.3147 0.03531 ft3 ft3

1 litre 1 litre
1 kPa = 100~Pa 1 bar 1 kPa 1 bar 1 Pa 1 mm.w.g. 11mm.w.g.

0.2199 Imp. Gallon 1 bar = 1000 mbar = 100 kPa

PRESSURE
1 Ib/in2 11~b/in2 1 In.w.g. 1 in.w.g. 1 in.w.g = = = = =

1 PSI = 2.307 FT
6895 Pa 68.95 mbar I 249.1 Pa 2.491 mbar 25.4 mm.w.g.

-33.45 fl w.g. = 0.3345 ft. w.g. = 14.5 ib/in2 = 0.3858 in.w.g. = 0.0394 in.w.g. = 9.8 Pa.w.g. 0.03937 in 3.281 ft 1.094 yard 0.6214 mile
0.00155 in2 0.155 in2 1550 in2 10.76 ft2

1 inch 1 ft

1 yard
1 mile
1 in2

25.4mm 0.3048 m 0.9144 m 1.609 km


645.2 mm2 6.452 cm2 929 cm2 0.0929 m2

= 1000mm 1mm = 1m = 1m = 1 km =
1 mm2
1 cm211 m2,1 m2

1 in2
1 ft2i1
ft2

'FLOW RATE 1 gall/min = 1 ft3/min = 1 ft3/min = TEMPERATURE


IDF to DC =

1 kg/sec = 1 litlsec @ OOC reference temperature 1 liUsec = 13.2 gall/min 0.07577 liUsec 1 liUsec = 2.119 ft3/min 0.4719 liUsec 1 m3/sec = 2119 ft3/min 0.02832 m3/sec
I

("X"DF -32)

x 0.5556

to of 11C
I

("X"OC x 1.8) + 32

DIFFERENCE
"X"DF x 0.5556 = DC

= 1K "X" C x 1.8 = 1 kg

OF

WEIGHT
I Ib

cwt ton

0.4536 kg 50.8 kg 1016kg

1 tonne 1 tonne

2.205 Ib 0.9842 ton 2204.6 Ib

.: !VOLUME !LENGTH I~ 1c 'TEMPERATURE J. i1m


1 I

For furtherdetajlson

Potterton Commercial boiler products contactthe

following:-

f I
PottertonCommercial Brooks House Coventry Road WARWICK CV34 4LL Products Dtvision Tel: (08706) 050607 Fax: (08706) 001516 Sales Direct Lihe:(08706) 001991 Technical Djrect Line: (08706} 002322 e-matl: commercialbotlers@potterton.co...uk Websfte: www.potterton.co.uk/commercral

COMMERCIAL SERVICE OFFICES Our serv!ce organisation covers the whole of the U.K, to look after your needs for all Potterton CommerciafProducts.. We are alsoabfe to offer our services for other manufacturers products. SOUTHERN REGION Potterton Commercial Service Dept , Un!t 2...Borehamwood Enterprise Centre Theobald Street BOREHAMWOOD Herts WD6 4RQ !el:{O8702) 412759 NORTHERN REGION Pottertbn Commercial Service Dept. Unit 102" Batley EnterpriseCehtre 513 Bradford Road BATLEY , -" WestYorksh.rreWF178JY Tel: (08702} 412759 Fax: (01924 )420276

I ::
"
cic.

Fax: (02082)072466

Our service offices offer a wide range ofspeciaJised servtcesincludjng:Boi.ler.SlteAss~mbly Burner Commiss1oningfor Burne r&BoiJ erRepJace mem Oil/GasConversjons System Condttioni ng Water Treatment & Descaling Packaged Units

all Fuels

Breakdown & Repair Services Bo11erDismantling & Re-Joint.ing

Potte~oriCommercial t a:,.

)hroughthe

Potterton Myson..lnterpart

Division
'

BaxlParis
Brooks House, Coventry Road WARWICK Warwickshire CV34 4LL

OR

Curzon Components Nationa1 Spares Hotline 0990 10 30 30


c

Tel: (08706) 000454


Fax: (08706)000545

improvements

inthi$ leaflet have been carefully prepared but we reserve the fight to make changes and in our proquct which may affect theact~racyofthe information contained..in this leaflet"

BaxiHeating

Ltd. Reg;Office: Sceptre Way, Bamber Bridge, Preston ~ Registered in England, No.3879156

.. ..

'AJldescrfptionsand..illustrationscontafned