Potterton Osprey 2 CFL 125 User guide

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

2
Natural Gas
Potterton Osprey 2 CFL 125
G.C.No41 590 54
Potterton Osprey 2 CFL 150
G.C.No41 590 55
Potterton Osprey 2 CFL 180
G.C.No41 590 56
Potterton Osprey 2 CFL 220
G.C.No41 590 57
The boiler meets the requirements of Statutory
Instrument “ The Boiler (Efficiency) Regulations
1993 No3083” and is deemed to meet the
requirements of Directive 92/42/EEC on the energy
efficiency requirements for new hot water boilers
fired with liquid or gaseous fuels:-
Type test for purpose of Regulation 5 certified by:
Notified Body 0049.
Product/Production certified by:
Notified Body 0049.
For GB/IE only.

3
1.0 Introduction 4
2.0 General Layout 5
3.0 Technical Data 6
4.0 Dimensions 7
5.0 System Details 8
6.0 Site Requirements 10
7.0 Installation 13
8.0 Commissioning the Boiler 15
9.0 Servicing the Boiler 17
10.0 Changing Components 19
11.0 Illustrated Wiring Diagram 23
12.0 Fault Finding 24
13.0 Short Parts List 28
Section Page
Contents

Potterton declare that no substances harmful to
health are contained in the appliance or used
during appliance manufacture.
1.1 Description
1. The Potterton Osprey 2 CFL is a fully automatic
gas fired floor standing conventionally flued boiler
with a cast iron heat exchanger.
2. The boiler is designed for use with fully pumped
open vented or sealed water systems with an
indirect hot water cylinder.
3. The boiler is available in outputs of 35.0, 43.0,
52.8 and 64.5kW
4. It is designed for use on Natural Gas (G20).
5. The boiler data badge is positioned on the boiler
inner front panel.
6. The boiler is intended to be installed in
residential / commercial / light industrial E.M.C.
environments on a governed meter supply only.
7. All systems must be thoroughly flushed and
treated with inhibitor (see section 6.2).
1.2 Installation
1. The appliance is suitable for installation only in
G.B. and I.E. and should be installed in accordance
with the rules in force. For Ireland install in
accordance with I.S.813 “Installation of Gas
Appliances”. The installation must be carried out by
a CORGI Registered Installer or other competent
person and be in accordance with the relevant
requirements of current Gas Safety (Installation
and Use) Regulations, the Building Regulations
(Scotland) (Consolidation), the Local Building
Regulations, the Current I.E.E. Wiring Regulations
and the bye laws of the Local Water Undertaking.
Where no specific instructions are given, reference
should be made to the relevant BRITISH
STANDARD CODES OF PRACTICE.
1.0 Introduction
4
“Benchmark” Log Book
As part of the industry-wide “Benchmark”initiative all Baxi boilers now
include an Installation, Commissioning and Service Record Log Book.
Please read the Log Book carefully and complete all sections relevant to
the appliance and installation. These include sections on the type of
controls employed, flushing the system, burner operating pressure etc.
The details of the Log Book will be required in the event of any warranty
work. Also, there is a section to be completed at each subsequent regular
service visit. The Log Book must be left with the user.
Fig. 1
NOTE: This appliance must be installed in
accordance with the manufacturer’s instructions
and the regulations in force. Read the instructions
fully before installing or using the appliance.
Inner Front Panel
Data Badge

2.0 General Layout
5
2.1 Layout
1. Flue Spigot
2. Draught Diverter
3. Cable Clamp
4. Flue Safety Thermostat
5. Flow Connection
6. Return Connection
7. Burner
8. Gas Inlet Connection
9. Burner Ignition Control
10. Boiler Drain and Cap
11. Gas Valve
12. Burner Manifold
13. Pilot Feed Pipe
14. Pressure Test Point
15. Pilot
16. Overheat Thermostat
17. Boiler Thermostat
18. Inner Front Panel
19. Control Panel
20. Cleaning Brush
21. Heat Exchanger
22. Flue Hood
23. Boiler Safety Overheat Neon
24. Flame Failure Neon
25. Burner On Neon
26. Power On Neon
27. Boiler Safety Overheat Reset
28. Flame Failure Reset
29. On/Off Button
30. Temperature Control
RESET ON / OFF
Osprey 2 RESET
Fig. 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
27 30
2524
28 29
26
Fig. 3

3.0 Technical Data
6
Outercase Dimensions
Casing Height - 850mm
Casing Width (125) - 600mm
Casing Width (150) - 695mm
Casing Width (180) - 790mm
Casing Width (220) - 885mm
Casing Depth (125/150) - 600mm
Casing Depth (180/220) - 650mm
Clearances
LH Side 150mm Min
RH Side 150mm Min
Top 700mm Min
Front 700mm Min
Rear 200mm Min
Weights kg
125 140
150 170
180 200
220 230
Connections
Gas Supply - 22mm compression
Flow - 11/4”steel pipe, taper thread
Return - 11/4”steel pipe, taper thread
Recommended System
Temperature Drop 11°C20°F
Maximum Flow Temperature
85°C
Heat Output 125 150
kW 35.0 43.0
Btu/h 119,443 146,745
180 220
kW 52.8 64.5
Btu/h 180,189 220,117
Electrical Supply 230V~ 50Hz
Power Consumption 25W
(excluding pump)
External Fuse Rating 3A
External Controls 230V switching
Electrical Protection IP20
(Appliance must be connected to an
earthed supply)
Appliance Category CAT 2H
Gas Rate 125 150
m3/h 4.0 5.06
ft3/h 142 179
180 220
m3/h 6.0 7.3
ft3/h 212 258
Burner Pressure 125 150
mbar 11.2 ± 0.4 11.4 ± 0.4
180 220
mbar 11.0 ± 0.4 11.8 ± 0.4
Inlet Pressure (Natural Gas Only)
mbar 20
in wg 8
Burner Injector
2.6mm Diameter
Appliance Type B11BS
NOxClass
150 & 180 3
125 & 220 2
This value is used in the UK Government’s
Standard Assessment Procedure (SAP) for
energy rating of dwellings. The test data from
which it has been calculated have been
certified by 0049.
SEDBUK Declaration For
Potterton Osprey 2 CFL
The seasonal efficiency (SEDBUK)
125: 78.6 %
150: 78.0 %
180: 78.3 %
220: 78.0 %
60
40
20
0
0102030405060
125
150
Flow Rate (l/min)
Pressure Drop (mbar)
70 80
125 and 150
60
80
100
120
40
20
0
0102030405060
180
220
Flow Rate (l/min)
180 and 220
Pressure Drop (mbar)
70 80 90 100 110 120
Heat Input (gross) 125 150
kW 43.07 53.28
Btu/h 146,983 181,827
180 220
kW 64.82 79.69
Btu/h 221,209 271,956 Water Content litres
125 24
150 29
180 33
220 38
Working Head
Minimum 0.5m
Maximum 30m (3 bar)
Flue Spigot Diameter
125/150 184mm
180/220 241mm
Hydraulic Resistance Charts
Pilot Injector
0.45mm Diameter

4.0 Dimensions
7
Dimensions (mm)
A
600
695
790
885
Model
125
150
180
220
B
332.5
380
427.5
475
C
850
850
850
850
D
511
511
511
511
E
600
600
650
650
A
C
B
D
E
Front Side
Fig. 4 Fig. 5
F
F
184
184
241
241

5.0 System Details
8
5.1 Primary Circuit
1. The appliance is suitable for fully pumped
systems only. The system can be open vented
or sealed.
2. A sealed system must incorporate the
following:-
•Safety Valve
•Pressure Gauge
•Expansion Vessel
•Filling Point
Reference must be made to the specific sections
of BS5449 relating to sealed systems.
Treatment of Water Circulating Systems
•All recirculatory water systems will be subject
to corrosion unless an appropriate water
treatment is applied. This means that the
efficiency of the system will deteriorate as
corrosion sludge accumulates within the system,
risking damage to pump and valves, boiler noise
and circulation problems.
•For optimum performance after installation this
boiler and its associated central heating system
must be flushed in accordance with the
guidelines given in BS 7593 “Treatment of water
in domestic hot water central heating systems”.
•This must involve the use of a proprietary
cleanser, such as BetzDearborn Sentinel X300
or X400, or Fernox Superfloc. Full instructions
are supplied with the products, but for immediate
information please contact BetzDearborn (0151
420 9563) or Fernox (01799 550 811) directly.
•For long term protection against corrosion and
scale, after flushing it is recommended that an
inhibitor such as BetzDearborn Sentinel X100,
or Fernox MB-1 or Copal is dosed in accordance
with the guidelines given in BS 7593.
Failure to flush and add inhibitor to the system
may invalidate the appliance warranty.
•It is important to check the inhibitor
concentration after installation, system
modification and at every service in accordance
with the manufacturer’s instructions. (Test kits
are available from inhibitor stockists.)
•For information or advice regarding any of the
above contact the Potterton Helpline.

5.0 System Details
9
5.2 Bypass
1. The boiler is fitted with a pump overrun device
which allows the removal of residual heat from
the boiler. The system design must therefore
always provide an open circuit to allow water
circulation between the boiler flow and return.
2. Any bypass must be capable of allowing a
minimum flow rate of 8l/min and be able to
dissipate at least 2kW.
5.3 System Control
1. The boiler is intended for use in a heating
system that incorporates external controls, i.e. a
minimum of a timer device.
2. For optimum operating conditions and
maximum economy the fitting of room and
cylinder thermostats is recommended.
3. The boiler should be controlled so that it
operates on demand only.

6.0 Site Requirements
10
6.1 Information
1. The installation must be carried out by a
CORGI Registered Installer or other registered
competent person and be in accordance with the
relevant requirements of the current Gas Safety
(Installation and Use) Regulations, the Building
Regulations (Scotland)(Consolidation), the Local
Building Regulations, the current I.E.E. Wiring
Regulations and the bye laws of the Local Water
Undertaking. Where no specific instruction is
given reference should be made to the relevant
British Standard Codes of Practice. For Ireland
install in accordance with IS 813 “Installation of
Gas Appliances”.
6.2 B.S. Codes of Practice
WARNING - The addition of anything that
may interfere with the normal operation of the
appliance without the express written
permission of Potterton could invalidate the
appliance warranty and infringe the Gas
Safety (Installation and Use) Regulations.
6.3 Clearances (Fig. 6 & 7)
1. Minimum clearances must be provided around
the boiler as follows:-
Each Side - 150mm
Top - 700mm
Front - 700mm
Rear - 200mm
Fig. 6
Fig. 7
STANDARD
B.S. 6891
B.S. 5440: Pt 1
B.S. 5440: Pt 2
B.S. 5546
B.S. 7074
B.S. 5449
B.S. 6798
SCOPE
Gas Installation.
Flues.
Ventilation
Installation of hot water supplies
for domestic purposes.
Expansion vessels and ancillary
equipment for sealed water systems.
Forced circulation hot water systems.
Installation of gas fired boilers.
700mm
700mm
700mm
200mm
150mm
150mm
Minimum Side
Clearances
Minimum Front &
Rear Clearances