JACKSON GAS WATER BOILER OWNER S MANUAL Click here for Parts List Country of Destination GB and IE Manual Part No: 930031-01 Gas Water Boiler - 1
Model No. Product Description Rev. Date Jackson Water Boiler JG220R3 Expansion Boiler 1 11/05/00 Manual Part No: 930031-01 Gas Water Boiler - 2
INDEX Page Cover Sheet: 1 Revision Sheet: 2 Index: 3 Introduction: 4-5 Specification 6 7 Specification 6 Overall Dimensions 7 Installation Instructions: 8 10 Unpacking 8 Preliminary Cleaning 8 Location 8 Data Plate 8 Gas Supply 9 Water Supply 9 Overflow Connection 10 Operational Check 10 Precautions 10 User Instructions: 11 13 Important Note 11 Operation 12 Service 13 Daily Cleaning 13 Servicing Instructions: 14 26 Index 14 Technical Description 15 Fault Finding Chart 16-18 Instructions 19 26 Spare Parts List: 27-30 Accessories: 31 Warranty Cover Sheet: 32 Manual Part No: 930031-01 Gas Water Boiler - 3
INTRODUCTION This manual contains all the required information to ensure that your new appliance is installed and serviced correctly and that you have all the information necessary to identify and order spare parts. It also contains comprehensive instructions for the user and for cleaning the appliance. To maintain peak performance, it is recommended that the appliance be regularly serviced and that when ordering spare parts, reference is made to the appropriate list quoting the Part Number and Description contained therein. THE FITTING OF A NON STANDARD PART MAY VOID ANY GUARANTEE. All work carried out on this appliance during installation or servicing must be performed by a competent person and the connection of the appliance to the gas supply MUST be carried out by qualified personnel in accordance, where applicable, with the relevant regulations. The siting of the appliance and the connection to the gas supply must comply with the latest GAS SAFETY (INSTALLATION & USE) REGULATIONS 2000: the requirements of the FIRE PRECAUTIONS ACT 1971; the HEALTH & SAFETY AT WORK, ETC ACT 1974, the BUILDING STANDARDS (SCOTLAND) CONSOLIDATION REGULATIONS 1971. Detailed recommendations are contained in British Standards BS5440 Part 1:2000, BS5440: Part 2:2000, BS5588: Part 0:1996, BS5588: Part 11:1997 & BS6173: 2001. An easily accessible stopcock must be fitted in the gas supply adjacent to the appliance for use in emergency. The details of the gas supply will be found on the Data Plate, which is located at the bottom front corner on the right hand side Improvements The policy of Viscount Catering Ltd is such that, each product is subject to continual development and may, therefore, be subsequently improved. The company reserves the right to alter the design of any appliance without prior notification and without the responsibility to update any delivered or in-service appliance and furthermore, without incurring the responsibility for altering these instructions. In such circumstances, it may be found that the appliance detailed herein differs in certain respects from the one supplied. IT IS IMPORTANT, THEREFORE, TO QUOTE THE SERIAL No. AND THE APPLIANCE MODEL No. IN ALL COMMUNICATIONS WITH THE COMPANY. Manual Part No: 930031-01 Gas Water Boiler - 4
Introduction (cont.) Important Before installing any item please refer to the installation instructions. We recommend that all servicing other than routine cleaning be carried out by out authorised service agents and will accept no responsibility for work carried out by other persons. For satisfactory operation, parts of catering equipment become hot. Suitable precautions must be taken to avoid accidental burns therefore the appliance should be positioned to minimise the possibility of accidental touching. It is the supervisors responsibility to warn users to wear suitable protection and to follow correct operation and cleaning procedures. For the details of your nearest Service Agent for all warranty repair work, you should contact:- The Service Manager, Viscount Catering Limited Provincial Park Nether Lane Ecclesfield Sheffield S35 9ZX Tel: +44 (0) 114 2574500 Fax: +44 (0) 114 2574527 Spares can be obtained via the Spare Parts Department at the above address. IT IS IMPORTANT, TO QUOTE THE SERIAL No. AND THE APPLIANCE MODEL No. IN ALL COMMUNUCATIONS WITH THE COMPANY Manual Part No: 930031-01 Gas Water Boiler - 5
SPECIFICATION The G220R3 Gas Heated Expansion Boiler will deliver 220 pints of boiling water per hour. Both Natural Gas and LG gas versions are available. The mains water supply should be connected to the ½ BSP mains inlet connection at the top right of the unit. Gas Pressure: Natural Gas 9.6 mbar (3.8 w.g.) Propane Gas 37mbar (14 w.g.) Heat Input (Nett) Model kw/hr Btu/hr Bypass kw/hr Output/hr G220R3-NG 1.572m 3 /hr 14.855 50,685 1.0 220 Pints 124 Litres G220R3-LP 1.043kg/hr 13.322 45,454 1.0 220 Pints 124 Litres Burner Injectors Natural Gas Propane Gas Main 1.50 mm 0.82 mm Bypass 0.82 mm 0.55 mm Weight Empty - 24.8 kg (54.6 lbs) Full - 31.5 kg (69.5 lbs) Water Connection and Level Control The float valve controlling the water level in the cistern and boiler is designed to operate at all pressures up to 200 p.s.i. but it is advisable not to use pressure below 10 p.s.i. for the safe operation of the boiler. Manual Part No: 930031-01 Gas Water Boiler - 6
Specification (cont.) Manual Part No: 930031-01 Gas Water Boiler - 7
INSTALLATION Important Your attention is drawn to the latest GAS SAFETY (INSTALLATION & USE) REGULATIONS 2000. This appliance MUST be installed by a competent person in accordance with these and any other relevant regulations. Users, too, should be aware of the regulations governing the use of gas appliances, particularly with respect to the need for regular servicing. 1) Unpacking Remove all wrapping and packing materials from the exterior and interior of the unit. 2) Preliminary Cleaning All the Stainless Steel exterior surfaces are covered with a plastic protective film, which MUST be removed before operating the unit. Peel the film off manually, and then clean the exposed Stainless Steel with a cloth moistened with white spirit to remove the tacky adhesive remaining. CAUTION: WHITE SPIRIT IS INFLAMMABLE 3) Location The boiler must be fixed to a level surface (see drawing for hole positions). Where possible a drip tray should be sited in front of the boiler and the waste water PIPED away using the waste union in the tray. If a drip tray is not fitted, the overflow should still be PIPED away to avoid any damage if the boiler overfills. Important: Any overhanging shelf, fitment or ceiling should be at least 450mm (18 ) above the flue outlet and must be non-combustible or protected from heat by suitable cladding. Adjacent surfaces should be fireproof and resistant to discoloration. The boiler should be stood on a surface made of non-combustible material e.g. metal and a minimum clearance of 150mm (6 ) should be left between the adjacent wall and either side of the appliance for service access. The boiler is unsuitable for direct connection to an external flue, but it should be installed in a SUFFICIENTLY WELL VENTILATED ROOM to enable the removal of steam. The flue outlet must be free from obstruction so that the boiler will work correctly. 4) Data Plate This is located at the bottom front corner on the right hand side. Check that the information stamped on the data plate matches the gas supply. Manual Part No: 930031-01 Gas Water Boiler - 8
Installation (cont.) 5) Gas Supply The gas inlet to the appliance is 15mm and the supply pipe should not be less than this. ENSURE THAT ALL SUPPLY PIPING IS CLEAR OF RUST, DUST AND SWARF BEFORE CONNECTING UP. Use jointing material sparingly and avoid coating the first two threads of any connecting pipe. Gas Pressure Adjustment a) Adjust the governor, if necessary, to give correct burner-operating pressure. The governor is included in the gas control train at the rear of the boiler. b) The pressure test nipple is on the down tube between the relay valve and the burner. The pressure should be as follows: - Natural Gas 9.6 mbar (3.8 w.g.) Propane Gas 37 mbar (14.0 w.g.) c) Remove the cover nut on the governor. i) To increase pressure, screw the adjuster inwards (clockwise). ii) To decrease pressure, screw the adjuster outwards (anti-clockwise). d) Replace the cover nut and re-tighten. 6) Water Supply The water supply connection is ½ BSP male. THE BOILER MUST BE CONNECTED TO RIGIDLY SUPPORTED METAL PIPEWORK TO ENSURE STABILITY. If copper piping is used, it must be at least 15mm diameter. A union and stopcock should be fitted in such a manner that unauthorised persons will not operate it and as close to the boiler as possible for servicing purposes. IT MUST NEVER BE TURNED OFF WHEN THE BOILER IS IN USE. However, if the supply is accidentally turned off, the boiler has a safety cut-out, which will switch off the gas to the burners. Should the water supply be re-connected, the gas will remain off until manually re-lit All boilers are supplied fitted with a float valve suitable for water pressures from 60-200 p.s.i. To convert to lower pressures, 10-60 p.s.i, exchange the plastic screw provided for the one in the float inlet orifice (use a pair of long nose pliers to extract the high pressure screw). THIS APPLIANCE IS NOT RECOMMENDED FOR USE WITH WATER PRESSURES BELOW 10 p.s.i. Do not use white or red lead for making joints on water fittings. Before connecting the cold water supply pipe, flush out to ensure removal of all jointing materials and foreign matter. Manual Part No: 930031-01 Gas Water Boiler - 9
Installation (cont.) 7) Overflow Connection (3/4 Internal diameter) Overflow should be connected to a warning pipe where discharge of water can readily be seen without it endangering property or personnel. 8) Operational Check a) Ensure that the water supply is connected and turned on to the boiler. b) Check that the cistern is full to the level marked inside. c) Light the boiler in accordance with the lighting instructions fitted to the front of the boiler. d) Check output - approximately 3 1 /2 pints per minute. e) Draw boiling water from the appliance and check that the gas is cut off approximately 30 seconds after the water supply is turned off. If the flame is not extinguished, check for faults as outlined in pages16-18 of the Service Instructions. 9) Precautions Ensure that the exterior panels are replaced correctly after commissioning. ANY UNAUTHORISED MODIFICATION MAY IMPAIR THE SAFETY OF THE APPLIANCE AND WILL INVALIDATE THE GUARANTEE. Manual Part No: 930031-01 Gas Water Boiler - 10
USERS INSTRUCTIONS Important The attention of the user is drawn to the requirements of the latest GAS SAFETY (INSTALLATION & USE) REGULATIONS 2000. This appliance MUST be used in accordance with those, particularly so in respect of the need for regular servicing. See also the sections of this manual referring to Cleaning and General Maintenance. Safety Note This appliance is intended for professional use and shall only be used by qualified personnel. Parts and surfaces of this appliance get hot in use. It is the responsibility of the kitchen supervisor to inform and warn every user and kitchen worker of this and, furthermore, to ensure those users wear and use protective clothing when operating the appliance. Should any adjustment or attention be necessary, you are advised to contact your nearest CORGI (Confederation for the Registration of Gas Installers) Service Engineer immediately. The need for regular servicing is detailed in the latest GAS SAFETY (INSTALLATION & USE) REGULATIONS 2000. IF YOU THINK THAT GAS IS ESCAPING, ACT IMMEDIATELY. SHUT OFF THE GAS SUPPLY AT THE METER OR EMERGENCY CONTROL, CONTACT THE SUPPLIER OF YOUR GAS IMMEDIATELY. MAKE SURE THAT ALL USERS OF THIS APPLIANCE KNOW WHERE THE GAS SUPPLY STOPCOCK IS LOCATED FOR THE USE IN AN EMERGENCY. Improvements The policy of Viscount Catering Ltd is such that each product is subject to continual improvement. The company reserves the right to alter the design of any appliance without prior notification and without the responsibility to update any delivered or in-service appliance and, furthermore, without incurring the responsibility for altering these instructions. In such circumstances, it may be found that the appliance detailed herein differs in certain respect from the one supplied. For further details or enquires please contact: Viscount Catering Limited, Provincial Park, Nether Lane, Ecclesfield, Sheffield, S35 9ZX Tel: +44 (0)114 2570100 Fax:+44 (0)114 2570251 Manual Part No: 930031-01 Gas Water Boiler - 11
Users Instructions (cont.) Before Operating the Boiler 1) Ensure that the water supply is turned on. 2) Before lighting the boiler from cold, open the draw-off tap and drain any still water that has remained in the boiler from the previous use. This will enable boiling water quantities to be available faster and will replace de-aerated water. 3) Close the draw tap off. Operation 1) Turn on the gas supply. 2) Press the White button (RH side rear) and apply a lighted taper to the centre ribbon (maintenance flame) of the burner. 3) Hold button depressed for a further 20 seconds to establish flame. 4) If flame is extinguished on releasing button, repeat steps 2 & 3. Note: When first lighting the appliance after installation or after an extended shut-down period, it may be necessary for the White button to remain depressed for some time before the pilot will light, owing to presence of air in gas line. 5) With a vessel under the draw- off tap, pull down the handle and the rest of the burner should now light. Important Notes 1) If the gas cock is turned off or the flames are extinguished for any reason, WAIT 3 MINUTES BEFORE ATTEMPTING TO RE-LIGHT. 2) DO NOT obstruct the steam vent on the boiler, it could be dangerous to do so. 3) There is a low water safety device in the form of a float in the built in cistern. If there is a shortage of water the gas will be cut off automatically. It will not be possible to re-light the boiler until the water supply is resumed. Output The maximum delivery is shown in the table: Available for rapid draw-off after Continuous delivery per Initial Pre-heat Time pre-heating hour (Minutes) PINTS LITRES PINTS LITRES 3 Continuous draw-off 220 124 Note: The above figures depend on local conditions and correct maintenance and are subject to manufacturing tolerances and periodic de-scaling in hard water areas. Manual Part No: 930031-01 Gas Water Boiler - 12
Users Instructions (cont.) Service The Installation Engineer should leave the appliance in good working order, however, in the event of transit damage or the failure of any part to operate during the warranty period, IT SHOULD BE REPORTED PROMPTLY to the installer or supplier, giving the details stamped on the Data Plate and the date of installation. The Data Plate is located at the bottom front corner on the right hand side. Note: In hard water areas, it is essential when the boiler is installed to arrange regular service visits to prevent damage caused by the build up of scale inside the boiler. This should be carried out by an experienced and competent Service Engineer- THIS WORK IS NOT COVERED BY THE GUARANTEE AS IT IS BEYOND OUR CONTROL. For the details of your nearest Service Agent for all warranty, repair and de-scaling work, you should contact: - The Service Manager, Viscount Catering Limited Provincial Park Nether Lane Ecclesfield Sheffield S35 9ZX Tel: +44(0)114 2570100 Fax:+44(0)114 2570251 Spares can be obtained via the Spare Parts Department at the above address (see illustrated Spare Parts list at the rear of this manual). Daily Cleaning 1) Wipe down the exterior surfaces with a cloth moistened with hot water and detergent. Rinse off using a cloth moistened with clean water and dry with a soft cloth. 2) DO NOT use abrasives. 3) DO NOT use wire wool. 4) DO NOT clean the appliance using a steam jet or water jet. 5) Proprietary cleaning pads may be used with care for removing heavy deposits if necessary. Manual Part No: 930031-01 Gas Water Boiler - 13
SERVICE AND MAINTENANCE Index Page Index 14 Technical Description 15 Fault Finding 16 18 Service Instructions: To Remove Outer Case Lid 19 To Remove Top Trim 19 To Remove the Gas Toggle Valve 19 Leakage from the Gas Toggle Valve 19 To Adjust Gas Toggle Valve 20 To Drain the Boiler 20 To Remove Cistern (Cold Water Feed Tank) 20 To Adjust the Water Level 21 To Replace Float Valve Diaphragm 21 To Remove Heat Exchanger and Circulating Sleeve 21 To Remove Thermocouple 21 To Remove Main Burner 22 To Remove Inner Sleeve 22 To Replace Outer Case 22 To Remove the Gas Control Train (Relay, FFD and Governor) 23 To Replace the Relay Valve Diaphragm 23 To Replace FFD Valve Solenoid 23 To Test the Operating Gas Pressure 23 To Adjust Operating Gas Pressure 24 To Remove the Low Water Cut Out Float 24 To Dismantle Boiling Water Draw Off Tap 24 General Notes on Descaling 25 To Convert NG Appliance to LP Gas 26 To Convert LP Appliance to NG 26 Manual Part No: 930031-01 Gas Water Boiler - 14
Service and Maintenance (cont.) Technical Description The boiler is fitted with a highly efficient heat exchanger which will maintain a continuous flow of boiling water (self feeding from a built in cistern), low water safety cut-out and automatic gas control. The gas is controlled by means of a governor controlling the operating gas pressure; a flame failure device (FFD) operated by the maintenance flame (centre ribbon) and a relay valve operated by a toggle valve mechanically linked to the boiling water draw-off tap handle. A fixed by-pass (maintenance rate) is incorporated into the FFD, which maintains the correct temperature of the water if the boiler is standing unused for long periods. Models are available for operation on both Natural and LP Gas. Manual Part No: 930031-01 Gas Water Boiler - 15
Service and Maintenance (cont.) Fault Finding Symptoms Fault Remedy Overboiling. Scale in boiling chamber. Descale. Defective toggle valve. Replace. Loose scale or dirt in draw-off tap. Clean draw-off tap. (Section 21) Broken spring in draw-off tap. Replace spring. (Section 21) Spindle defective in draw-off tap. Replace spindle. (Section 21) Water level too high. Adjust water level to level mark in Cistern. Gas pressure set too high. Adjust gas governor. (Section 19) Not delivering rated output. Gas pressure incorrect. Adjust gas governor. )Section 19) Draw-off tap not opening fully. Replace defective parts. (Section 21) Water level low. Adjust water level to level mark in cistern. Partial blockage of feed from Clean out. cistern. Float valve partly blocked. Clean valve. (Section 9) Not delivering boiling water. Steaming and no water being delivered. Water pressure low. Water flooding boiler chamber. Leaking soldered joints in boiling chamber. Water space between boiling chamber and heat exchanger blocked. Blockages in cistern trap (London Loop). Mains water supply turned off. Refer to installer. Adjust water level to level Repair or replace. (Section 9) Descale. (Section 22) Clean. (Section 7) Turn on. Float valve blocked. Clean. (Section 9) Manual Part No: 930031-01 Gas Water Boiler - 16
Service and Maintenance (cont.) Fault Finding (cont.) Symptoms Fault Remedy Main burner remains Dirt in float valve. Clean on. Float defective. Replace float valve. (Section 9) Float valve washer worm. Replace float valve. (Section 9) Float valve insert defective. Replace float valve. (Section 9) Waterways scaled up. Descale. (Section 22) Boiling when on bypass. Restrictor missing from by-pass Replace. pipe. Relay valve not closing. Rectify. (Section 16) Centre ribbon (maintenance flame) will not stay alight. Governor not set to correct pressure. Fault connection at thermocouple FFD valve. Thermocouple incorrectly positioned. Thermocouple defective. FFD Valve defective. Float set to low Adjust governor. (Section 19) Remake connection. (Section 11) Reposition thermocouple. Replace. Replace solenoid coil or valve. Reposition float to correct level. Main burner will not light Electric float switch faulty. Check continuity and connections. Replace if necessary. Relay valve bleed hole blocked. Clean relay valve. Gas toggle valve not opening. Adjust toggle valve. (Section 5) Gas feed tubes blocked. Dismantle tubes and clean. Main burner remains on. Gas toggle valve not closing. Adjust toggle valve. (Section 5) Gas leak on union. Rectify. Dirt on relay valve seating. Relay valve diaphragm split. Clean relay valve. Replace diaphragm. Manual Part No: 930031-01 Gas Water Boiler - 17
Service and Maintenance (cont.) Fault Finding (cont.) Symptoms Fault Remedy Water leaking onto main burner. Heat exchanger leaking. Replace. (Section 10) Overboiling. See Section 1 Fault Finding. Cold water feed pipes vibrating. Loose pipework to feed cistern. Loose jumper in stop tap. Refer to installer. Refer to installer. Flame does not extinguish when water is turned off. Electric float switch is faulty. Replace. (Section 20) Electric float switch is in the wrong Reposition float so that it attitude. hangs downwards. (Section 20). Short on thermocouple between spade Remove short or replace. connections. (Section 11) Faulty electromagnetic unit in FFD. Examine repair/free off or replace as necessary. (Section 17) Manual Part No: 930031-01 Gas Water Boiler - 18
Service and Maintenance (cont.) ENSURE MAINS GAS AND WATER SUPPLIES ARE TURNED OFF BEFORE COMMENCING SERVICING 1) To Remove Outer Case Lid a) Lift at rear of lid. b) Slide lid forward and lift clear. c) Replace in reverse order. Ensure the lip on lower front of outer case lid fits under the lip on the top trim. 2) To Remove Top Trim a) Remove outer case lid (Section 1). b) Remove the two M5 nuts and shakeproof washers. c) Lift the gas toggle valve lever and withdraw trim. d) Replace in reverse order. 3) To Remove the Gas Toggle Valve a) Remove the top trim (Section 2). b) Disconnect the two gas compression unions from the gas toggle valve. c) Ease the gas pipes away from the gas toggle valve. d) Slacken the locknut and turn the boiling water draw off tap so that it is horizontal. e) Hinge the gas toggle valve lever down so that it is vertical to the valve. f) Remove the hexagon locknut and shakeproof washer securing the gas toggle valve to its bracket. Detach valve. g) Replace in reverse order ensuring boiling water draw off tap is returned to its vertical position and that it operates the gas toggle valve lever when the tap is opened. 4) Leakage from the Gas Toggle Valve Should any problems due to leakage of gas, or mechanical breakage, is experienced with the toggle IT SHOULD BE REPLACED COMPLETELY. Manual Part No: 930031-01 Gas Water Boiler - 19
Service and Maintenance (cont.) 5) To Adjust Gas Toggle Valve a) Remove top trim (Section 2). b) Slacken the four Pozi drive screws securing the gas toggle valve bracket to the outer case. c) Ease the bracket up or down as required. d) Tighten the four Pozi drive screws. NOTE: There is only slight adjustment. 6) To Drain the Boiler a) Switch off the water supply. b) Remove outer case lid (Section 1). c) Insert a rubber hose down the cistern trap (London Loop). d) Siphon as much water as possible from the boiler. e) Disconnect the mains water supply union from the cistern ball valve. f) Disconnect the overflow pipe if fitted. g) Disconnect the mains gas union at the boiler gas stopcock. h) Lift the boiler at the front. Tilt the top back and withdraw counter tray from below base members (legs). i) Lift the boiler from its stand and invert it over a sink, to remove an water remaining in the boiling chamber. j) Replace in reverse order. 7) To Remove Cistern (Cold Water Feed Tank) a) Drain the boiler (Section 6a to e). b) Remove the outer case by undoing the six outer case screws and lifting the panel to the left of the appliance. c) Remove riser from bottom of cistern or alternatively disconnect the 15mm union at the cold water feed nosepiece at the rear of the boiler below cistern. d) Remove the two M5 x 25mm screws securing the cistern to the top of the outer case. Detach the cistern. e) Replace in reverse order. Ensure new packing washers are fitted where required, between the cistern and cistern trap. Manual Part No: 930031-01 Gas Water Boiler - 20
Service and Maintenance (cont.) 8) To Adjust the Water Level a) With the mains water supply turned on check the water level against the level indicator inside the cistern. b) Rotate Float spindle to adjust water level if required. 9) To Replace Float Valve Diaphragm a) Remove outer case (Section 1) b) Turn off water, disconnect water feed pipe from float valve remove back nut and washer, pull valve away from cistern. Replace in reverse order. c) To clean filter, remove float, unscrew retaining nut and remove arm and front cap assembly. Remove diaphragm and filter, wash filter and assemble valve in reverse order, ensuring filter is pushed fully back over it s slot, hand tighten only. 10 To Remove Heat Exchanger and Circulating Sleeve a) Drain broiler (Section 6). Remove cistern (Section 7). b) Remove cold water feed nose-pipe from rear of boiler by unscrewing it anti-clockwise. c) Remove the boiling water draw off tap by unscrewing the hexagon locknut. d) Remove the draw off tap nosepiece. Unscrew nosepiece anti-clockwise taking care not to mark the front of the boiler. e) Lift out the circulating sleeve from the heat exchanger. Note the position of the three locating lugs fitting into the slots on the top edge of the inner sleeve. 11) To Remove Thermocouple a) Remove the rear panel and outer case lid (Section 1 & 7b). b) Disconnect the low water cut out float from the thermocouple. c) Remove the two M5 screws securing the access cover to the lower front panel d) Disconnect the thermocouple from below the flame failure device. e) Remove the two hexagonal screws from the clamping bracket and lift off the bracket front. Lift out the thermocouple. f) Replace in the reverse order. Note the positioning of the flats and recesses on the components when reassembling. Manual Part No: 930031-01 Gas Water Boiler - 21
Service and Maintenance (cont.) 12) To Remove the Main Burner a) Drain the boiler (Section 6) and disconnect water feed, overflow and gas feed pipes ensuring supplies are isolated. b) Remove the thermocouple (Section 11). c) Invert the boiler. d) Disconnect the maintenance injector pipe located at the rear of the main burner. e) Disconnect the compression union fitted into the side of the main burner. f) Disconnect the 15mm compression union at the relay valve. g) Remove the two M5 screws and washers securing the burner to the bottom of the outer case. Detach burner. Replace in reverse order. 13) To Remove Inner Sleeve a) Remove heat exchanger and circulating sleeve (Section 10). b) Remove main burner (Section 12). c) Turn the boiler the correct way up. d) Turn the inner sleeve so that the lower positioning bracket s attached to the lower edge of the sleeve clear the outer case lip. Lift the sleeve up and remove from top. Replace in reverse order. 14) To Replace Outer Case a) Remove heat exchanger and circulating sleeve (Section 10). b) Remove main burner (Section 12). c) Remove inner sleeve (Section 13). d) Lift out outer sleeve. e) Remove the four M5 screws securing the gas toggle valve bracket to the outer case. f) Remove the gas supply pipes connecting the gas toggle valve to the gas controls and main burner. g) Replace in reverse order. Manual Part No: 930031-01 Gas Water Boiler - 22
Service and Maintenance (cont.) 15) To Remove the Gas Control Train (Relay, FFD and Governor) a) Remove the lid and the outer case. b) Switch off and disconnect the supplies. c) Disconnect the thermocouple from below the FFD valve. d) Disconnect the compression union from the top of the relay valve. e) Remove the inlet and outlet 15 mm compression unions. f) Detach the control train for examination. Before splitting the parts note their arrangement and the angles made between them. g) Replace in the reverse order. 16) To Replace the Relay Valve Diaphragm a) Remove the lid and outer back. b) Disconnect the union on the top of the valve. c) Remove the four screws securing the top of the relay valve. d) Detach the top of the valve and lift out the diaphragm. e) Fit new diaphragm and replace in reverse order. 17) To Replace FFD Valve Solenoid a) Disconnect the thermocouple from below the FFD valve. b) Unscrew the hexagon plug from bottom of FFD valve. c) Withdraw solenoid. d) Fit new solenoid and replace parts in reverse order. 18) To Test the Operating Gas Pressure a) Remove the hexagon headed screw from the test point. b) Fit a flexible tube to test point and connect it to a manometer (U tube). c) Turn on the main s gas and light the boiler. d) Open the boiling water draw off tap and position a container under the nozzle spout. e) Check that the burner is full on. The pressure at the manometer should be 3.8 wg (9.6 mbar). g) Close the boiling water draw off tap. Turn the gas off. Remove the tube and refit the hexagon screw to pressure point. Manual Part No: 930031-01 Gas Water Boiler - 23
Service and Maintenance (cont.) 19) To Adjust Operating Gas Pressure a) Proceed as in Section 18. b) Remove the cap nut on the governor. c) To increase the pressure turn the screw clockwise. To decrease the pressure turn it anticlockwise. d) Secure the cap nut after adjusting the governor. 20) To Remove the Low Water Cut Out Float a) Switch off the supplies. b) Remove the lid and outer case back. c) Remove the push on tags from the thermocouple. d) Undo the back nut and remove the float. e) Replace in the reverse order. 21) To Dismantle Boiling Water Draw Off Tap a) Open draw off tap and drain water from collecting box. b) Slacken the locknut and turn the draw off tap through 90. c) Unscrew bonnet and lift out upper assembly. (If changing the seat cup only, pull it off the stem and press on a new one. Replace the upper assembly). d) With the seat cup attached to the upper assembly place the seat cup in the palm of the hand, press down with the fingers on top of the cam thus compressing the spring. Push out the handle pin with a small screwdriver from the hole in the cam. e) Remove the spring from the stem. f) Detach the seat cup from the stem by pulling it off. g) Replace in reverse order, fitting new parts as required. Note: The handle pin must be fitted as shown. Manual Part No: 930031-01 Gas Water Boiler - 24
Service and Maintenance (cont.) 22) General Notes on De-scaling If hard water is used, it is essential that the boiler should be de-scaled at regular intervals, depending on the hardness and usage of the boiler. As a general rule, complete de-scaling should take place every three months. Dismantling the appliance and removing the scale by mechanical means. The use of a chemical solvent is not recommended except in the special case mentioned later in these instructions. A coating of scale will lower the efficiency and shorten the life of the heat exchanger if it is not removed. The heaviest deposits of scale will be found in the following places: a) The bore of the draw off tap. b) The boiling water collecting box. c) On the inside of the heat exchanger. d) The cistern trap (London Loop) and union. To De-scale the Boiler a) Remove the heat exchanger and circulating sleeve (Section 10). b) Remove any scale from inside the heat exchanger by gently chipping it off. Ensure all the scale is removed from the base. Wash away any loose scale with cold water. c) Remove the scale from the circulating sleeve and ensure the vent pipe in the collecting box is clear. d) The cold water feed and draw off tap nosepieces may be drilled out with a suitable sized masonry drill to clear the scale. e) The cistern trap can be cleared by using a drill on an extended handle, it is very important that the cistern trap is cleared of any scale. f) The boiling water draw off tap may be immersed in a solution made with a proprietary brand of descalant. Immersion should not be prolonged beyond the time necessary to allow the scale to be removed. It should be noted that this method of de-scaling is suitable for lightly scaled items only. g) After de-scaling, all the components should be swilled in cold water. h) Replace in reverse order. Manual Part No: 930031-01 Gas Water Boiler - 25
Service and Maintenance (cont.) 23) To Convert NG Appliance to LP Gas a) Remove the lid and the outer case. b) Switch off and disconnect the supplies. c) Remove burner (Section 12) and fit replacement LP burner, (200289) complete with 0.82mm injectors and 0.55mm by-pass injector. d) Disconnect gas supply pipe to governor and remove. e) Disconnect governor from FFD. f) Fit new gas supply pipe and union. 24) To Convert LP Appliance to NG a) Remove the lid and outer case. b) Switch off and disconnect the supplies. c) Remove burner (Section 12) and fit replacement NG burner, (200290) complete with 1.5mm injectors and 0.82 mm by-pass injector. d) Disconnect gas supply pipe union. e) Fit replacement gas governor, elbow and gas supply pipe. d) Adjust gas pressure (Section 19). Manual Part No: 930031-01 Gas Water Boiler - 26
SPARE PARTS LIST Item No. Description Part No. 1 Outer Back & Side Panel 315902 2 Gas Cock 303457 3 Gas Inlet Pipe NG 317115 3a Gas Inlet Pipe LP 329218BO 3b Straight Adapter - LP 304054 4 Elbow 15 mm x ½ BSP 305064 5 Burner Gas Inlet Pipe Assembly 206165 5a Pressure Test Nipple X03030 6 Governor (½ ) NG X03041 7 Flame Failure Device (FFD) X04046 8 Relay Valve 209751 9 Elbow ½ BSP Iron 305056 10 Stud Elbow 3 / 16 x 1 / 8 BSP 305066 11 Base Member LH 301422 12 Base Member RH 301441 13 Supply Pipe Support Strap 327503 15 Thermocouple 209271 16 Thermocouple Bracket 927074-01 17 Burner Assembly NG 200290 17a Burner Assembly LP 200289 18 Burner Supply Pipe Support 207861 19 Access Hole Cover Assembly 201978 20 Draw Off Tap Assembly & Nozzle 208856 20a Draw Off Tap Assembly w/o Nozzle 208854 20b Tap Stem 327534 20c Tap Spring 327476 20d Tap Handle 308002 20e Tap Handle Pin 316631 20f Tap Seat Cup 303942 20g Nozzle Assembly c/w Locknut 205528 20h Nozzle Locknut Only 314603 21 Outer Case Assembly 201979 22 Outer Sleeve 327030 23 Top Trim 328761 24 Toggle Valve Bracket 302810 25 Toggle Valve Assembly with Lever 209809 25a Toggle Valve Lever 312312 25b Lever Locating Pin 316710 25c Locknut ¼ BSP 314769 25d Stud Coupling 1 / 8 x 3 / 16 927780-01 25e Compression Nut 3 / 16 927780-02 Manual Part No: 930031-01 Gas Water Boiler - 27
Spare Parts List (cont.) Item No. Description Part No. 26 Inner Sleeve Assembly 207098 27 Heat Exchanger Assembly 200248 28 Nose Piece for Draw Off Tap 316636 28a C Ring 318505 28b Coupling Nut 314586 29 Circulating Sleeve/Collecting Box 201517 30 Heat Exchanger Lid Assembly 207250 31 Outer Case Lid 312454 33 Float Valve 330066 34 Side Panel 316303 35 Cistern Overflow 205500 36 Cistern Assembly 201976 37 Low Level Water Indicator 309011 38 Straight Coupling 15 mm x ½ BSP 303915 38a Riser 318600 38b Sealing Washer 331010 39 Trap Assembly Un-plated 209291 40 Plug 1 / 8 BSP 317605 40a Seating Washer for Plug 331031 41 Elbow 15 mm x ½ BSP 305013 42 Water Inlet Nose Piece 316490 42a Sealing Washer 331010 43 Counter Tray 328697 44 Straight Coupling 303633 Items Not Illustrated 50 Fascia Panel Fixing Plate 205774 Supply Tube Assembly 51 Toggle Valve to Relay Valve 930169-04 52 Toggle Valve to Inlet Adapter 930169-05 53 FFD to Maintenance Injector 930169-06 Spares Kits Conversion Kit NG to LPG 927617-G31 Conversion Kit LPG to NG 927617-G32 Manual Part No: 930031-01 Gas Water Boiler - 28
Spare Parts List (cont.) Manual Part No: 930031-01 Gas Water Boiler - 29
Spare Parts List (cont.) Spare Parts available from: Viscount Catering Ltd Provincial Park Nether Lane Ecclesfield Sheffield S35 9ZX Tel: +44 (0) 114 2574550 Fax: +44 (0) 114 2574520 Manual Part No: 930031-01 Gas Water Boiler - 30
ACCESSORIES XB269429 XB269435 XB269455 XB269456 XBJE-DCV Stand Assembly Drip Tray Swivel Arm Extension 300mm Swivel Arm Extension 230mm Double Check Valve Manual Part No: 930031-01 Gas Water Boiler - 31
VISCOUNT CATERING LIMITED WARRANTY COVER The Company offer twelve months warranty with each new piece of equipment subject to our normal conditions of sale and will undertake responsibility for warranty subject to the additional following conditions. Notice of the defect/damage is given within 48 hours of breakdown or in the case of damage four days from the date of despatch and the manufacturer given adequate opportunity to examine the goods in order that appropriate action can be taken. The Company will not be obliged to repair or replace any goods if after examination the defect/damage is found to be through accident, misuse, neglect, incorrect installation or maintenance by other than approved engineers, or any other cause beyond the reasonable control of the manufacturer. EXCLUSIONS TO WARRANTY Normal routine maintenance is not covered and the warranty specifically excludes any problems, which are related to scale caused by hard water and the cleaning of pilot jets. Also excluded from the warranty are the following consumable items. Tap washers and springs, gaskets, oven lamps and indicating lights, door seals and any other perishable parts. This warranty in no way prejudices your rights under common law and is offered as an addition to your statutory rights. Manual Part No: 930031-01 Gas Water Boiler - 32