Potterton Illusion Installation and maintenance instructions

Part No. 966/9350/1 – 02
Potterton Housewarmer Illusion ASD - G.C. NO. 37 590 16
966 Inset DGF with ILLUSION FACIA
Potterton Housewarmer Stratton ASD - G.C. NO. 37 590 17
966 Inset DGF with STRATTON FACIA
Potterton Housewarmer Presence ASD - G.C. NO. 37 590 18
966 Inset DGF with PRESENCE FACIA
Installation & Service Instructions
Inset Decorative Gas Fire for use with the
Potterton Housewarmer 45 & 55 BBu's
THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1994.
‘‘In your own interest, and that of safety, it is law that all gas appliances are installed by competent persons,
in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution.’’
The polythene bags used for packaging are a potential hazard to babies and young children
and MUST BE DISPOSED OF IMMEDIATELY.
LEAVE THESE INSTRUCTIONS WITH THE USER FOR USE ON FUTURE CALLS
For Use With Natural Gas
(G20) Only At 20mbar
For Use in GB & IE
IMPORTANT
PLEASE READ THIS BOOK
BEFORE INSTALLING,
OPERATING OR
SERVICING THIS
APPLIANCE.

Contents - Page 2
1. Technical Data...................................................................................................................................................................3
2. General...............................................................................................................................................................................4
3. Installation Requirements................................................................................................................................................4
3.1 Fireplace Openings......................................................................................................................................................4
3.2 Hearths, Walls, Fire Surrounds, Shelves & Clearances...............................................................................................5
4. Installation.........................................................................................................................................................................6
4.1 Unpack the Fire ........................................................................................................................................................6
4.2 Disassemble the Fire................................................................................................................................................6
4.3 Prepare the Fire........................................................................................................................................................7
4.4 Install the Convector Box, Blanking Panel & Burner Tray .......................................................................................8
4.4.1 Convector Box................................................................................................................................................8
4.4.2 Blanking Panel................................................................................................................................................8
4.4.3 Burner Tray & Gas Supply.............................................................................................................................9
5. Installing the Firebed Ceramics ......................................................................................................................................9
6. Check Gas Pressure & Operation of the Fire...............................................................................................................10
7. Test for Spillage..............................................................................................................................................................10
8. Fitting the Facia ..............................................................................................................................................................11
9. Complete the Installation ...............................................................................................................................................12
10. Servicing & Cleaning......................................................................................................................................................13
11. Replacement of Parts.....................................................................................................................................................14
11.1 General Access ......................................................................................................................................................14
11.2 Pilot Burner Assembly ............................................................................................................................................15
11.3 Burner Injector........................................................................................................................................................16
11.4 Lint Trap..................................................................................................................................................................16
11.5 Piezo Unit ...............................................................................................................................................................16
11.6 Gas Tap..................................................................................................................................................................17
12. Short List of Spares........................................................................................................................................................19
If you have any problems or questions concerning this appliance, please contact the
Potterton Myson Technical Help Line - Telephone [phone].

1. Technical Data - Page 3
Illusion Stratton Presence
Weight - Packed - Fire 23.90kg (52.7lb). 23.90kg (52.7lb). 23.90kg (52.7lb).
Weight - Unpacked - Fire 18.98kg (41.8lb). 18.98kg (41.8lb). 18.98kg (41.8lb).
Weight - Packed - Facia 21.25kg (46.8lb). 17.00kg (37.5lb). 8.30kg (18.3lb).
Weight - Unpacked - Facia 19.29kg (42.5lb). 15.10kg (33.3lb). 5.30kg (11.6lb).
Gas Connection ¼" Male Flare via Boiler Isolation Valve at Right Hand side of fire.
Tap Combined Tap, Flame Supervision Device and Piezo.
Burner Simplex - Fixed Aeration - Mica Filled Tray.
Injector - Burner Marked Bray CAT 28/340
Injector - Pilot Sit OxyPilot
Pressure Test Point On Pipework at Left Hand Side of Fire.
Spark Gap 3 - 4mm - Pre-set, Non Adjustable.
Gas Rate on Setting 'HI' 0.49 m³/h (17.29 ft³/h).
Heat Input on Setting:- 'LO' 3.8kW ( 12,965Btu/h).
'HI' 5.4kW ( 18,425Btu/h).
Heat Output on Setting:- 'LO' 0.96kW ( 3,275Btu/h).
'HI' 1.5kW ( 5,118Btu/h).
Burner Pressure on 'HI' - Cold 17.3 ± 1.0mbar (6.9 ± 0.4in w.g.).

2. General - Page 4
The 966 is an inset decorative gas fire. It is lit by a piezo spark igniter so batteries or electricity are not required. When fitted
with either the Illusion, Stratton or Presence Facia, this fire is only suitable for use with the Potterton Housewarmer 45 & 55
BBu's.
The decorative effect is created by the use of ceramic coals mounted on a ceramic bed that glows red when heated by the
burner. Samples of the fire have been examined by British Gas Plc, a United Kingdom Notified Body. The range is certified
to comply with the essential requirements of the Gas Appliance Directive 90/396/EEC and are therefore permitted to carry
the CE Mark.
The fire is fitted with two safety features:-
a) A Flame Supervision Device that will shut down the fire if the gas supply is interrupted, the gas supply to the fire will
remain off until the fire is re-lit. Wait 2 minutes before re-lighting the fire.
b) An Atmospheric Sensing Device that will shut down the fire if the flue/chimney fails to operate correctly, e.g. blocked
flue. If the fire shuts down frequently and gas supply interruption is not the cause then the flue/chimney MUST BE
inspected and corrective action taken. Call you local Gas Region or C.O.R.G.I. Registered Installer.
IMPORTANT: Certain types of wallcoverings e.g. Blown Vinyl, are easily affected by heat. They may shrink and discolour
when close to a heating appliance. Please bear this in mind when installing the fire. Also, because of the
way hot air circulates naturally convected heat from the fire, dust or tobacco smoke particles in the air will
draw towards the wallcovering around the fire and may discolour it.
3.Installation Requirements - Page 5
3.1. Fireplace Openings.
The maximum size of the front opening of the fireplace
recess is 490mm wide x 580mm high. The minimum size is
the same as for the boiler.
A non-combustible infill panel may be used to reduce an
existing fireplace opening to the required dimensions.
Note: A proprietary fire surround back panel MUST NOT
be used as an infill panel as it would be exposed to
high temperature combustion products.
The minimum flat area will enable the outer metal surround
to be fitted correctly and give access to the boiler controls.
Note: Chimneys, Flues and Flue Systems are covered in the
Installation & Service Instructions supplied with the Back
Boiler Unit.

General - Page 5
3.2. Hearths, Walls, Fire Surrounds,
Shelves & Clearances.
Hearths
The fire MUST be installed onto a non-combustible
hearth. The hearth must be to the dimensions shown in
Fig. 2.
Walls
If the wall against which the fire is to be mounted has a
combustible cladding or surround, the following
conditions must be met:-
1. The cladding must fit snugly to the wall face, any air
cavities must be sealed to prevent air leakage into
the flue which would spoil the flue pull.
2. The cladding material must be cut away at the
edges of the fireplace opening. Under no
circumstances can it be present inside the fireplace
recess or in any other position which will allow direct
contact with the hot flue products.
Fire Surround
The surround’s fireplace opening and flat area must
comply with the dimensions shown in Fig. 2. It must be
sealed to the wall (and infill panel if fitted) correctly and
have no combustible material protruding within the
fireplace opening or exposed to the combustion
products.
Shelves
A combustible or non-combustible shelf can be fitted
above the fire provided it complies with the following
guidelines:
1. Any shelf up to 150mm in depth must be a minimum
of 85mm above the top of the fire.
2. Generally for every 10mm increase in shelf depth
the shelf height above the top of the fire must
increase by 10mm.
3. Any shelf 240mm in depth must be a minimum of
175mm above the top of the fire.
See Figure 3 for examples.
Clearances
In all installations there must be a minimum clearance of
115mm on both the left and right hand sides of the fire.
This will allow for air supply and access for operation of
controls and servicing.

4. Installation - Page 6
4.1. Unpack the Fire
The fire is supplied in 2 packs.
Pack 2 of 2 contains:-
1The Convector Box.
2Burner Tray.
3Spillage Plate.
4Outer Metal Surround.
5Ceramics Pack.
6Control Board Mounting Bracket.
7Bag of Fittings.
8Poly Bag containing these Instructions and other
literature.
Pack 1 of 2 contains:-
aThe Facia Assembly.
bThe Plinth Assembly.
cBlanking Panel.
dPoly Bag containing
4 location screws.
If any parts are damaged or missing please contact the
phone number shown on the check lists supplied with the
packs.
DO NOT discard the packaging until all items are accounted
for or the fire is installed.
4.2. Install the Surround and Controls
a) Stand the outer metal surround on the hearth and position up against the wall.
b) Ensure it is central about the fireplace opening and mark the 4 positions of the mounting holes on the wall.
c) Remove the surround, then using a 6 mm masonry drill, drill and plug the 4 marked mounting holes on the wall.
d) Attach the foam strip along the sides and top of the surround at the rear.
e) Using the 4 woodscrews supplied, secure the surround to the wall. Ensure the foam strip has been compressed.
f) Remove from the bag of fittings and secure the tap mounting bracket to the outer metal surround using the 2 M4 x 8mm
screws supplied.
g) Insert the gas fire isolation tap through the hexagonal opening in the tap mounting bracket located at the bottom right of
the surround and secure to the bracket using the locknut. Connect the gas fire supply pipe to the isolation tap. Ensure
the isolation tap is in the closed position.
h) Unplug the user control from the electronic control box on the boiler. Insert the 2 screws supplied into the user control,
feed the cable through the opening and locate the user control against the two slots in the surround. Tighten the screws
sufficiently to hold the control in place.
j) Connect the user control plug onto its socket on the electronic control box and secure the harness using the cable clips.
Insert the boiler overheat thermostat wire into the cable clips.

Installation - Page 7

Installation - Page 8

Installation - Page 9
4.4. Install the Convector Box
a) Attach the self adhesive foam strip along the sides and top of the outer edge of the convector box at the rear.
b) Hook the spillage plate over the top edge of the firebox as shown in figure 6 and secure using the 2 No.6 x 9.5mm
screws from the bag of fittings.
c) Position the convector box up against the outer metal surround. The bottom air box and upper spigot will locate inside
the combustion chamber front cover and flue hood extension on the boiler.
d) Using 4 of the M5 x 10mm screws from the bag of fittings, securely fasten the convector box to the outer metal
surround. Ensure that the foam strip has been compressed.
4.5. Assemble and Install the Burner Tray
a) Mount the Blanking Panel on to the Burner Tray using the 4 location screws.
b) Insert the Burner Tray into the convector box so it locates onto the studs at the front.
c) Using the wing nuts, secure the Burner Tray to the convector box.
d) Connect the inlet tube to the gas fire isolation tap. If necessary, the screws securing the isolation tap mounting bracket
can be loosened to allow slight movement when aligning the tube to the tap. Fully tighten the screws once the pipe has
been connected to the isolation tap.
e) Set the isolation tap to the On position, turn ON the gas supply and test the installation and all joints for gas soundness
then purge the installation in accordance with BS 6891.
5. Installing the Firebed Components - Page 9
Install the Vermiculite, Ceramic 'Coal Bed' and Ceramic
Coals as shown in the instruction sheet titled "Installing the
Firebed Components" (Part No. 966/9350/3) supplied with
the ceramic packs.
After installing those components return to these instructions
and carry on with the installation from Section 6.

6. Check Gas Pressure & Operation Of Fire - Page 10
The test point screw is located on the left hand side of
the controls assembly near the gas tap.
a) Remove the pressure test point screw and connect
a pressure gauge.
b) Push in and turn the control knob anti-clockwise to
the ' ' (ignition/pilot) setting and the pilot should
light. Keep the knob pushed in for 10 seconds then
release, the pilot should remain alight.
It may be necessary to repeat this operation several
times before all the air is purged from the line. Push
in and turn the knob clockwise back to ' OFF '
between each attempt.
c) Turn the control knob to setting ' HI '.
d) Check the burner pressure, it should be:-
17.3mbar ± 1.0mbar (6.9in w.g. ± 0.4in w.g.).
This pressure will only be obtained if the incoming gas
pressure is 20mbar (8in w.g.).
Check the size of the pilot flames, when lit the pilot flame
envelope should just cover the electrode tip and
thermocouple. If the flame is not as described, replace
as shown in Section 11.2.
e) Push in and turn the control knob through to 'OFF'.
f) Disconnect the pressure gauge, re-fit the pressure
test point screw and test for gas soundness
.
7. Test For Spillage - Page 10
1. Fire Only
a) Close all doors and windows, re-light the fire (pilot
now only visible in a reflected form, see Fig.12).
Then turn to the ' HI ' setting.
b) After 5 minutes light a smoke match and position
centrally as shown in Fig.9. The smoke should be
drawn into the flueway.
c) If in doubt, a re-check can be made for up to a total
of 15 minutes after lighting the fire.
d) If the fire shows a pronounced tendency to spill,
remove the fire and check that the spigot is securely
connected. Re-fit the fire and re-perform the test.
e) If the test still shows spillage, DISCONNECT THE
FIRE AND SEEK EXPERT ADVICE.
f) If there is an extraction fan in any room, this must be
turned on and any doors between it and the fire left
open, re-perform the test.
2. Fire & Boiler
Switch on the boiler and repeat the full test shown
above.
If the tests are successful, turn the fire off and complete
the installation.

8. Fitting The Facia - Page 11
a) Loosen the 2 facia fixing bracket screws
(1 each side) located at the bottom of the convector box
and slide the brackets towards the centre of the
appliance. Temporarily re-tighten the screws.
b) Lift the facia and position it centrally on the convector
box ensuring that the 2 lugs at the top of the facia locate
in the 2 holes at the top of the convector box.
c) Loosen the 2 facia fixing bracket screws, slide the fixing
brackets back towards the facia and hook the 'Claws'
onto the ridges on the inside of the facia. Tighten the
screws sufficiently to bring the facia parallel to the
fireplace wall.
Note: Removal is the opposite of installation.
NSTALLER
At this stage mark the appropriate facia type box on the data
badge with an indelible pen/marker.

9. Complete The Installation - Page 12
Locate the Plinth into position at the front of the appliance.
In the interests of hygiene please wash your hands on
completion of the installation.
Leave the bag of vermiculite with the consumer to allow
them to top up the burner tray.
Hand the Instructions For Use to the consumer and explain
the following points:-
a) How to light the boiler, how to light the pilot on the fire
and alter the settings. Also how to light the pilot using a
taper.
See Page 5 of the Instructions For Use.
b) The procedure for replacing the ceramic coals, and that
the fire must not be used if any of the ceramic coals or
other ceramics are missing or broken.
c) That any smell emitted from the fire and boiler is due to
the 'newness' and will disappear as the fire is used.
d) That inspection and servicing should be carried out at
regular intervals as recommended by your local British
Gas Region or C.O.R.G.I. Registered Installer. See
Instructions For Use, Page 8.
e) If service or spare parts are required, always quote the
Appliance Name, Serial Number and G.C. Number
shown on the Data Badge. Show the user the position of
the badge and advise them to write the Serial Number in
the space provided on Page 9 of the Instructions For
Use.
f) That after a time, the convector box inner, the ceramic
coals and other ceramic pieces will start to discolour,
this is quite normal and will enhance the appearance of
the fire.
g) That certain types of wall coverings, e.g. Blown Vinyl,
are easily affected by heat. They may shrink and
discolour when close to a heating appliance. They
should bear this in mind when decorating the room.
Also, because of the way hot air circulates naturally
convected heat from the fire dust particles or tobacco
smoke in the air will be drawn towards the wallcovering
around the fire and may discolour it.

10 Servicing & Cleaning - Page 13
Refer to the separate boiler instructions supplied with the boiler for cleaning the boiler.
To ensure continued efficient operation of the appliance, it is recommended that it is checked and cleaned as necessary at
regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage but in general
once per year should be adequate. It is the law that any service work must be carried out by a competent person such as
British Gas or other C.O.R.G.I. registered personnel.
The following aspects of the fire and installation should be examined and rectified as necessary.
1. Run the fire and check the operation of its controls and observe the flame picture.
2. Remove dust and debris from the burner, lint trap, A.S.D and fire interior.
3. Examine the burner injector and ensure it is clear and undamaged.
4. Carry out a spillage test, see Section 7, Page 10.
The fire data badge is located at the bottom left hand side of the convector box. The badge will be visible after removal of
the plinth. On completion of the service run the boiler and fire and ensure that they operate correctly.
WARNING:
Before commencing work, turn the fire off and set the boiler switch to off.
Isolate the electricity supply to the boiler and allow the fire and boiler to cool.
IMPORTANT:
Always test for gas soundness after completing any servicing of gas carrying components
and carry out functional checks of controls.
10.1 Remove the Fire
a) Perform General Access - See 11.1, Page 14.
b) Remove the screws securing the convector box to the outer metal surround and remove the convector box.
10.2 Inspect & Clean Components
a) Carefully brush off any dust or deposits from all the ceramic pieces. Examine all the ceramics and replace any that are
broken.
b) Remove and inspect the Burner Injector - See 11.3, Page 16. Clean by blowing through or washing. Do NOT clear the
injector with a pin or wire.
c) Check the condition of the Atmospheric Sensing Device, remove any deposits from the thermocouple tip using a fine
wire brush.
d) Check the condition of the self adhesive foam strips, replace if necessary.
e) Wipe any deposits from the stainless steel firebox inner using a damp cloth.
10.3 Re-fit the Fire
a) Re-fit the convector box and secure to the outer metal surround using the screws previously removed.
b) Re-fit the burner tray and secure to the convector box using the wing nuts previously removed.
c) Re-connect the gas supply, open the gas fire isolation tap and test for gas soundness.
d) Re-fit the vermiculite and ceramics as shown in the instruction sheet titled "Fitting the Firebed Components" (Part No.
966/9350/3) that was supplied with the ceramic packs.
e) Light the fire, test all joints around the fire for gas soundness, check the control tap operation and test for spillage
(Section 7, Page 10).
f) Clean the outer case of the fire as described in the Instructions for Use.

11. Replacement of Parts - Page 14
11.1. General Access
a) Carefully pull the plinth away from the fire.
b) Remove the facia (2) by slackening off or removing the
facia fixing brackets at the base of the facia. Lift the
facia off the convector box.
d) Carefully remove all the ceramics and place to one side.

Replacement of Parts - Page 15
c) Close the gas fire isolation tap and undo the union.
d) Loosen the 2 wing nuts securing the burner tray to the
convector box, then carefully remove the burner tray.
e) To avoid accidental spillage, carefully empty the
vermiculite (Ash Effect) out of the burner tray into a
suitable container and put somewhere safe.
On re-assembly, check the level of the vermiculite, if it is
below the level of the burner tray top surface, it will need
topping up - See instruction sheet 966/9350/3.
11.2. A.S.D Assembly
a) Perform General Access - 11.1.
b) Remove 2 screws securing the pilot sighting plate and
remove the plate.
c) Disconnect the union nut securing the pilot pipe to the
pilot injector with 2 spanners.
d) Disconnect the thermocouple from the back of the gas
tap.
e) Pull the electrode lead off the piezo unit.
f) Remove 2 screws securing the A.S.D assembly and
heat shield assembly to the burner box.
g) Fit the new A.S.D assembly and check that the spark
gap between the electrode tip and the thermocouple tip
is 3.0 to 4.0 mm. If necessary, adjustment can be made
by gripping the base of the tip with one pair of pliers
whilst gently bending the end of the tip with another pair.
Take care not to crack the ceramic insulator.
h) Re-assemble in reverse order, check for gas soundness
and correct operation of the fire.

Replacement of Parts - Page 16
11.3. Burner Injector
a) Perform General Access - 11.1.
b) Disconnect the union nut securing the pipe to the
injector carrier.
c) Remove the screw securing the injector carrier to the
injector box then carefully withdraw the injector carrier.
d) Unscrew injector from the injector carrier.
Notes on re-assembly - Use a suitable sealing compound
on the injector threads.
e) Check for gas soundness and correct operation of the
fire.
11.4. Lint Trap
a) Perform General Access - 11.1
b) Remove the screw securing the lint trap to the injector
box and carefully remove the lint trap.
11.5. Piezo Unit
a) Remove the Plinth.
b) Pull the control knob off the gas tap.
c) Remove the 2 screws securing the bezel around the gas
tap. Remove the bezel.
d) Pull the electrode lead off the piezo unit.
e) Pull the circlip off the gas tap spindle and slide off the
piezo unit.
f) Slide the new piezo unit onto the spindle.
Notes on re-assembly - The circlip locates in the groove on
the spindle just in front of the piezo unit. Ensure the
electrode lead is positively located.
h) Check for correct operation of the fire

Replacement of Parts - Page 17
11.6. Gas Tap
a) Perform General Access - 11.1.
b) Pull the control knob off the gas tap.
c) Remove the 2 screws securing the bezel around the tap. Remove the bezel.
d) Pull the electrode lead off the piezo unit.
e) Unscrew the thermocouple from the rear of the gas tap.
f) Disconnect the 3 union nuts at the gas tap.
g) Remove the 2 gas tap screws and withdraw the gas tap.
Notes on re-assembly - Ensure the electrode lead is positively located. The thermocouple connection need only be finger
tight and a quarter turn.
i) Check for gas soundness and correct operation of the fire.

12. Short List Of Spares - Page 18
Drg. G.C. Description No. Makers
Ref. No. Off Part No.
1389 583 Burner Injector - Bray CAT 28/340 1966/705
2158 582 Tap Assembly - Includes Drg. Ref. 3 1364/1044
3385 855 Piezo Unit 1942/9387
4127 293 Pilot Burner Assembly (Atmospheric Sensing Device) 1960/1433
5127 022 Control Knob Assembly 1503/1051
For Part Numbers of the ceramic bricks that make up the 'Coal Bed' and the ceramic coals refer to the instruction sheet titled
"Fitting the Firebed Components" - Part Number 966/9350/3
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