Installation & Service Instructions Profile

40eL - 80eL

About the Boiler See inside cover for models covered by these instructions.
This is a Wall Mounted Fan Assisted Balanced Flue Gas Boiler.
This boiler is for use with Natural Gas (G20) only at 20 mbar and for use in GB & IE.

About Safety The Gas Safety (Installation and Use) Regulations 1998.

‘‘ In your own interest, and that of safety, it is law that all gas appliances are installed by competent
persons, in accordance with the above regulations. Failure to install appliances correctly could
lead to prosecution.’’

Installation must be in accordance with the Installation & Service Instructions and the rules in
force.

Leave these instructions and the Benchmark Log Book with the user for use on future calls.

PRF0002A

TM

The code of practice for the installation,

commissioning & servicing of central heating systems
 Contents
Technical Data........................................................3
Introduction..................................................................4 The models covered by these instructions are:-
1. Installation Requirements................................4
1.1 Health & Safety Information...............................4 Profile 40eL - G.C. No. 41 590 50
1.2 Codes of Practice.............................................4 Profile 50eL - G.C. No. 41 590 51
1.3 Gas Supply.....................................................5 Profile 60eL - G.C. No. 41 590 52
1.4 Electricity Supply.............................................5 Profile 80eL - G.C. No. 41 590 53
1.5 Location of Boiler..............................................5
1.6 Air Supply.......................................................7
1.7 Flue Systems..................................................7
1.8 Flue Terminal Location......................................8
1.9 The System.....................................................9 The boiler model and serial number are given on labels; one
on the underside of the controls cover; the other to the right
2. Installation...................................................13 hand side of the thermsotat knob, and visible after removal
2.1 Unpack the Boiler and Flue..............................13 of the controls cover.
2.2 Fixing Template.............................................13
2.3 Boiler Mounting Plate......................................13 Potterton is a member of the Benchmark initiative and fully
2.4 The Flue.......................................................14 supports the aims of the programme. Benchmark has been
2.5 Air/Flue Duct Assembly...................................14 introduced to improve the standards of installation and
2.6 Prepare the Boiler...........................................15 commissioning of central heating systems in the UK and to
2.7 Install the Boiler.............................................16 encourage the regular servicing of all central heating
2.8 Connect System Pipework..............................18 systems to ensure safety and efficiency.
2.9 Overheat Thermostat Bulb Position..................19
2.10 Electrical Connections....................................19 Important – Failure to install and commission this appliance
2.11 Fitting Side Infill Panels..................................20 to manufacturer’s instructions may invalidate the warranty.
This note does not affect your statutory rights.
3. Commissioning............................................21
3.1 Commission the Boiler....................................20

4. To Service the Boiler (s) & Component

Replacement (r) .................................................25
4.1 (s) Prepare Boiler for Servicing.........................26 Note: Boiler Clearances are shown on Page 5 and
4.2 (s) Heat Exchanger......................................26 Boiler Dimensions are shown on Page 7
4.3 (s) Pilot Burner...............................................26
4.4 (s) Combustion Chamber Insulation..................27
4.5 (s) Main Burner...............................................27
4.6 (s) Fan...........................................................27
4.7 (s) Case Seal..................................................27
4.8 (r) Gas Control Valve.......................................28
4.9 (r) Fan...........................................................28
4.10 (r) Main Burner................................................28
4.11 (r) Pilot/Ignition Electrode.................................28
4.12 (r) Combustion Chamber Insulation...................29
4.13 (r) Fuse..........................................................29
4.14 (r) Electronic Control.......................................29 SAFETY, PERFORMANCE & QUALITY
4.15 (r) Pressure Switch.........................................29 Profile boilers have been assessed by a Government
4.16 (r) Overheat Thermostat..................................30 appointed Notified Body and shown to meet the
4.17 (r) Boiler Thermostat.......................................30 'Essential Requirements' of the European Gas
4.18 (r) GravityHW/Pump Overrun Thermostat..........30 Appliance Directive.
4.19 (r) Heat Exchanger Pipe Seal............................30
The Directive lays down requirements for the safety
and efficiency of the appliance, together with its
5. Fault Finding......................................................32 design, construction, and use of materials.
It also requires the production process to be covered
6. Optional Extras and Accessories.....................33
by an approved and monitored system of quality
7. Short List of Spares...........................................34 assurance.

2 Contents Publication No. 5105703

 Technical Data

Boiler model

40 50 60 80

Output kW (Btu/h) 11.72 (40,000) 14.65 (50,000) 17.58 (60,000) 23.45 (80,000)

Input kW (Btu/h) max 14.42 (49,200) 18.02 (61,500) 21.66 (73,900) 28.88 (98,500)

Gas rate m³/h (ft³/h) max 1.34 (47.5) 1.68 (59.4) 2.02 (71.3) 2.69 (95.1)

Burner Pressure max 12.3 (4.9) 11.5 (4.6) 13.0 (5.2) 12.2 (4.9)
mbar (in wg)

Injector Size mm 3.1 3.5 3.8 4.4

Maximum Working Head 30.5 m (3 bar)

Minimum Working Head 305 mm
Minimum Circulating Head - Gravity 1.2 m
Gas Supply Pressure 20 mbar
Gas Supply Connection Rc. ½ (½ in BSP Female)

Maximum Flow Temperature 82 °C

Flow/Return Connections 28 mm copper
Water Content 6.5 litres

Appliance Weight Installed - Lift 53.0 kg

- Dry 62.0 kg

Electricity Supply 230 v ~ 50 Hz Fused at 3A

Internal Fuse Type 1A
Power Consumption 80 Watts (excluding pump)
SEDBUK Declaration for Profile
Classifications CAT I 2H
2H G20 20 mbar Model Seasonal Efficiency
(SEDBUK) (%)
C13, C33
IP20 40L 78.0
50L 78.0
60L 78.2
80L 78.4

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 0063.

Publication No. 5105703 Technical Data 3

 Introduction
Gas Safety (Installation & Use) Regulations 1998. The boilers are for use on Natural Gas (G20) only.

This appliance must be installed and serviced by a competent Samples of the Profile gas boilers have been examined by
person, in accordance with the above regulations. Advantica Technologies Limited, a United Kingdom Notified
Body. The range is certified to comply with the essential
In the UK 'Corgi' Registered Installers (including the regions requirements of the Gas Appliance Directive 90/396/EEC,
of British Gas Plc) undertake to work to a safe and the Low Voltage Directive 72/23/EEC and shows compliance
satisfactory standard. with the Electro Magnetic Compatibility Directive 89/336/
EEC, the Boiler Efficiency Directive 92/42/EEC and are
Failure to install appliances correctly could lead to therefore permitted to carry the CE Mark.
prosecution.
Delivery & Kits Available
It is in your own interest, and that of safety, to ensure that
the regulations are complied with. The unit is delivered in two packages (1) the boiler with
fittings and (2) the flue/terminal assembly. All boilers can be
Profile boilers are fully automatically controlled, wall supplied with either of the following types of flue system:
mounted, fan powered, balanced flue appliances using a
cast iron heat exchanger and are available in outputs • Standard horizontal flue system suitable for wall thickness
ranging from 11.72 - 23.45 kW (40,000 - 80,000 Btu/h) of 100 mm to 510 mm.
• 2 metre horizontal flue system which provides a maximum
The boilers which are designed to provide domestic hot flue length of 1955 mm.
water and/or central heating must be used on INDIRECT hot • Vertical flue system which allows the flue to pass
water systems only. The cast iron heat exchangers are through a flat roof and terminate at a maximum height of
suitable for use on open vented gravity domestic hot water/ 1980 mm measured from the top of the boiler case.
pumped central heating systems or fully pumped systems
which may be sealed or open vented. Various kits are available for the Profile range of boilers, see
page 33.
Before installing the boiler on a gravity domestic hot water
system, consult the current building regulations as to any
restrictions.

1. Installation Requirements

1.1 Health and Safety Information for the Precautions - Dust goggles will protect eyes. People
Installer and Service Engineer with a history of skin complaints may be particularly
susceptible to irritation. High dust levels are only likely
Under the Consumer Protection Act 1987 and Section 6 of to arise following harsh abrasion. In general, normal
the Health and Safety at Work Act 1974, we are required to handling and use will not present high risk, follow good
provide information on substances hazardous to health. hygiene practices, wash hands before, touching eyes,
consuming food, drinking or using the toilet.
Small quantities of adhesives and sealants used in the First Aid - Medical attention must be sought following
product are cured and present no known hazards. eye contact or prolonged reddening of the skin.

The following substances are also present. Thermostat

Insulation and Seals Material - Contains very small quantity of xylene.

Description - Sealed phial and capillary containing
Material - Man Made Mineral Fibre. liquid.
Description - Boards, Ropes, Gaskets. Known Hazards - Irritating to skin, eyes and throat.
Known Hazards - Some people can suffer reddening Vapour is harmful. Inflammable - do not extinguish with
and itching of the skin. Fibre entry into the eye will water.
cause foreign body irritation which can cause severe Precautions - Do not incinerate. Avoid contact with
irritation to people wearing contact lenses. Irritation to broken/leaking phials. Do not purposely puncture.
respiratory tract. First Aid - Medical attention must be sought following
eye/skin contact, wash with clean water.

4 Introduction/Installation Requirements Publication No. 5105703

1.2 Codes of Practice The boiler is suitable for installation to a combustible wall
e.g. wood cladding, provided that the flue duct is not closer
The boiler must be installed in accordance with: The Gas than 25 mm to combustible material. A metal sleeve should
Safety (Installation and Use) Regulations 1998 and the be installed to surround the flue duct to provide a 25 mm
current issue of:- annular space. Further guidance is given in BS5440:1:2000,
sub-clause 4.4.
The Building Regulations, Building Standards (Scotland)
Regulations, Local Building Regulations, Model and local If the boiler is to be installed in a timber framed building it
Water Undertaking Bye-laws, IEE Wiring Regulations and should be fitted in accordance with the Institute of Gas
Health & Safety Document No. 635 "The Electrician At Engineers document IGE/UP/7/1998 (also, British Gas
Work Regulations 1989". Service publication Part 19 - Building and Kitchen Work). If
in doubt advice must be sought from Potterton.
1.3 Gas Supply The boiler may be installed in any room, although particular
attention is drawn to the requirements of the current IEE
The meter and supply pipes must be capable of delivering Wiring Regulations and, in Scotland, the electrical provisions
this quantity of gas in addition to the demand from any other of the Building Standards applicable in Scotland with
appliances in the house and must be governed at the meter. respect to the installation of the boiler in a room containing
a bath or shower.
The complete installation must be tested for gas soundness
and purged as described in BS6891. Where a room-sealed appliance is installed in a room
containing a bath or shower, any electrical switch or
1.4 Electricity Supply appliance control, utilising mains electricity should be so
situated that it cannot be touched by a person using the bath
230V ~ 50Hz via a fused double pole switch with a contact or shower.
separation of at least 3 mm in both poles adjacent to the
boiler. Power consumption is approximately 80W. There Where the installation of the boiler will be in an unusual
must be only one common isolator for the boiler and its position, special procedures may be necessary and BS6798
control system and it must provide complete electrical and BS5546 give detailed guidance on this aspect.
isolation.
A cupboard or compartment used to enclose the boiler must
Fuse the supply at 3 A. The minimum requirement for the be designed and constructed specifically for this purpose.
power supply cable is that it should be a PVC sheathed cord An existing cupboard or compartment may be used provided
at least 0.75 mm² (24 x 0.2 mm) (code designation HO5 VV- that it is modified for the purpose. Details of essential
F or HO5 VVH2-F) as specified in table 16 of BS6500:1984. features of cupboard/compartment design including airing
cupboard installations are given in BS6798 and BS5546
All wiring external to the boiler shall comply with the latest and should be complied with.
IEE Wiring Regulations, and any local regulations which
apply. The boiler requires the clearances shown after installation
for correct operation and servicing:
WARNING: THIS APPLIANCE MUST BE EARTHED.
Front: 610 mm
In the event of an electrical fault after installation of the Sides: 5 mm
boiler, preliminary electrical systems checks must be Top: 50 mm unless optional pump cover is fitted
carried out i.e. Earth Continuity, Short Circuit, Polarity and when clearance should be 178 mm
Resistance to Earth. Bottom: 100 mm

1.5 Location of Boiler Additional clearances are required during installation of

this boiler and 127 mm is required at the top for access
The boiler is not suitable for external installation and should to the pipe connections.
not be fitted directly above a cooking appliance.

The boiler must be installed so that the flue terminal is

exposed to the external air. It is important that the position
of the terminal allows the free passage of air across it at all
times.

The boiler must be mounted on a flat wall which is sufficiently

robust to take the weight of the boiler.

Publication No. 5105703 Installation Requirements 5

 Flow Pipe Fan Return Pipe

Fan Mounting
WARNING
Plate
F F
Fan Supply
Leads
Gravity DHW/
Pump Over-run
Thermostat Overheat
Capillary Thermostat
Capillary

Air Pressure Heat Exchanger

Pipe

Boiler Fan Lead &

Drain Cap Overheat
Thermostat
Capillary
Ignition Retaining Clip
Electrode

Combustion
Chamber
Pilot

Main Burner

Thermostat
Capillary Air Deflector
Retaining Clip Channel
PRF0001A

Gravity DHW/
Pump Over-run
Thermostat

Control Box
Gas Cock
Code Badge

Gas Control Valve Burner Pressure System Overheat Test Control

Test Point Change-Over Thermostat Socket Thermostat
Switch

Fig. 1

6 Installation Requirements Publication No. 5105703

 *50 (60) *300
'A' Return (310) 50
'B' 'C'
Flow

170
'D' 64

700 *125 600

(135)

Electrical
*25
PRF0003A

Connections (35)
Inside Control
Box 100

*30 (40) Gas Connection

148 R.c½
(½" BSP Female)
Model 40 50 60 80
* Note: If pipework is to be run down the back of the boiler, the
normal clearance of 28 mm between the rear of the boiler and
Dimension 'A' 425 425 425 425 wall can be increased to 38 mm if desired by inverting the boiler
(mm) 'B' 150 150 150 150 mounting plate during installation.

'C' 143 143 143 143 Dimensions in brackets ( ) apply when the mounting plate is
'D' 87 87 107 107 inverted.
Fig. 2

1.6 Air Supply

The air requirements must meet BS 5440 Part 2.

The room in which the boiler is installed does not require a purpose provided air vent.

Ventilated Cupboard/Compartment: If the boiler is installed in a cupboard or compartment, permanent air vents are
required in the cupboard or compartment, one at high level and one at low level, either direct to the outside air or to a room.
Both high level and low level air vents must communicate with the same room or must be on the same wall to outside
air. Both the high level and low level vent must each have a free area as stated below. The free area of each vent may
be halved if the ventilation is provided directly from outside.

Models: 340: 135 cm² 'x'

50: 170 cm²
60: 206 cm²
80: 277 cm²

If the boiler is installed in a cupboard or compartment with a door, allow

at least 15 mm clearance between the front of the boiler and the door
for air movement.

1.7 Flue Systems

PRF0006A

The flue system can be run from either the left, right, rear or top of the
boiler.

Maximum Length 'X'

Standard Flue 510 mm

2 Metre Flue 1995 mm
Fig. 3

Publication No. 5105703 Installation Requirements 7

1.8 Flue Terminal Location

M
D,E
L C

G G
B
F
K,N

FLU0001A
F
P A
A
H J J
G

Likely flue positions requiring

a flue terminal guard
Fig. 4

• Where a horizontal flue is sited less than

Horizontal Terminal Position with Minimum Distance (mm)
2 m above a balcony, above ground, or
above a flat roof to which people have Fanned Draught Balanced Flue
access, a suitable terminal guard must be
fitted. This serves two purposes, to protect A Directly below an opening, air brick, 300
the terminal against damage or opening window etc
interference and to protect passers-by. A B Above an opening, air brick, opening window, etc 300
C Horizontally to an opening, air brick, 300
terminal guard is available (Part No. opening window etc
205792), this should be fitted centrally D Below a gutter, or sanitary pipework 75
about the terminal. E Below the eaves 200
F Below a balcony or carport roof 200
G Above ground, roof or balcony level 300
Note: Where a flue terminal is installed H From vertical drain/soil pipe work 150
less than 1 metre from a plastic, or painted J From an internal or external corner 300
gutter, or 500 mm from painted eaves, an K From a surface or boundary facing the terminal 600
aluminium shield 1 metre long, should be L Vertically from a terminal on the same wall 1500
M Horizontally from a terminal on the same wall 300
fitted to the underside of the gutter or N From a terminal facing the terminal 1200
painted surface. A suitable wall plate P From an opening in a carport (e.g. door, windows) 1200
should be fitted to the painted wall surface into the building
of a mobile home.

• IMPORTANT: It is absolutely
ESSENTIAL, to ensure that products of Reduced Clearances
combustion discharging from the terminal
The Profile range of boilers has been tested and approved for use
cannot re-enter the building, or any other
with certain clearances less than those shown above.
adjacent building, through ventilators,
windows, doors, natural air infiltration, or Only one of these reductions may be used on a single
forced ventilation/air conditioning. If installation.
products of combustion are found to be re-
D Below a gutter, or sanitary pipework 25
entering any building, the appliance MUST E Below the eaves 25
be turned OFF IMMEDIATELY. F Below a balcony or carport roof 25
H From vertical drain/soil pipe work 75
J From an internal or external corner 25

8 Installation Requirements Publication No. 5105703

1.9 The System Combined Gravity Hot Water, Pumped Central Heating
Systems
If plastic pipe is used for the central heating circuit there
must be a run of at least 1 m of un-insulated copper pipe Where a cylinder thermostat and zone valve is used to
from the boiler flow and return connections. control the temperature of the hot water it is recommended
that a by-pass be installed in the gravity circuit. A
The boiler must be used on Indirect hot water systems only. suggested method of doing this is shown in Fig. 8 where
It is suitable for use on open vented gravity domestic hot the bathroom radiator is connected into the gravity
water/pumped central heating systems or fully pumped circuit and is fitted with two lockshield valves.
systems which may be sealed or open vented. Mechanically operated thermostatic domestic hot water
temperature control valves which allow the boiler to
The system should be designed so that the maximum static operate when the valve is closed or partially closed
head does not exceed 30.5 m (100 ft) and a minimum of 150 MUST NOT BE FITTED.
mm (6 in).
Fully Pumped Systems
Gravity domestic hot water circuits should have a minimum
circulating head of 1.2 m (4 ft). With the change-over switch in the control box set at the
FULLY PUMPED position, the pump will be controlled
To ensure optimum boiler performance on both gravity hot by an overrun thermostat. This will ensure that the
water and fully pumped systems a change-over switch is pump will continue to run after boiler shut down if the
incorporated in the boiler control box. The boiler is supplied water temperature is high, thus preventing nuisance
with the switch set for sealed or open vented fully pumped operation of the overheat thermostat.
systems.
If a three port valve is used as shown in Fig. 5 a by-pass
If the boiler is to be used on a system with gravity hot water is not necessary since one circuit is always open.
the switch must be set to the GRAVITY position. In
addition, the bulb of the overheat thermostat should be Where a pair of two port valves are used, a by-pass is
repositioned as shown in Fig. 21. necessary. The total length of the by-pass circuit taken
from the boiler connections should be greater than 4
To prevent reverse circulation in the gravity circuit when the metres of 22 mm pipe. It should be fitted with a
pump is running, an injector disc is provided to form an lockshield valve and be adjusted to maintain a minimum
injector tee at the return connection on the boiler, see Fig. flow through the boiler of 4.5 litres/min (1 gal/min).
20.
Systems fitted with controls which allow the boiler to
On all systems the pump live connection should be wired operate when both the hot water and central heating
to the boiler terminal block, it will then be controlled by the circuits are closed i.e. mechanically operated
pump overrun. This will ensure that the pump will continue thermostatic control valves, must be fitted with a by-
to run after boiler shut down if the water temperature is high, pass circuit of:-
thus preventing nuisance operation of the overheat
thermostat. 1. Dissipating a minimum of 1 kW (3400 Btu/h).
2. Maintaining a minimum water flow rate through the
It is important that where electrically operated zone valves boiler of 9 litres/min (2 gal/min).
are used the boiler is wired so it does not cycle when the
zone valves are closed. Also, systems fitted with controls A suggested method of meeting these requirements by
that close both hot water and central heating circuits while using a bathroom radiator fitted with two lockshield
the boiler is still hot, must be fitted with a by-pass circuit to valves is shown in Fig. 5. Additional system information
dissipate the residual heat from within the boiler. can be found in the Control Systems, pipework and
Wiring Guide.
Drain off taps should be fitted in the pipework close to the
boiler and in the low points of the system.

Note: Although the system can be emptied using the drain

off taps installed in the pipework around the system, to
empty the boiler it is necessary to remove the drain off cap
positioned within the boiler case.

Publication No. 5105703 Installation Requirements 9

Sealed Systems
The boiler flow temperature is controlled at approximately
Installation 82 °C. The vessel size can now be determined from the
The installation must comply with the requirements of information in Table 1 where V = System volume in
BS 6798: 1987 and BS 5449: Pt 1. The British Gas litres.
publication "British Gas Specification for Domestic
Wet Central Heating Systems" should also be consulted.
Vessel Charge Pressure (bar) 0.5 1.5
Pressure Relief Valve
A non-adjustable spring-loaded pressure relief valve, Initial System Pressure (bar) 1.0 1.0
preset to operate at 3 bar (45lbf/in²) shall be used. It
must comply with BS 6759: Pt 1. and include a manual Expansion Vessel Volume (litres) V x 0.11 V x 0.087
testing device. It shall be positioned in the flow pipe
Table 1.
either horizontally or vertically upwards and close to
the boiler. No shut-off valves are to be placed between
the boiler and the safety valve. The valve should be Cylinder
installed with a discharge pipe which permits the safe The hot water cylinder must be an indirect coil type or a
discharge of steam and hot water such that no hazard direct cylinder fitted with an immersion calorifier suitable
to persons or damage to electrical components is for operating at a gauge pressure of 0.3 bar (5 lbf/in²) in
caused. excess of safety valve setting. Single feed indirect
cylinders are not suitable for sealed systems.
Pressure Gauge
A pressure gauge incorporating a fill pressure indicator, Method of Make-up
covering the range 0 - 4 bar (60 lbf/in²) shall be fitted to Provision shall be made for replacing water loss from the
the system. It should be connected to the system, system either:-
preferably at the same point as the expansion vessel.
Its location should be visible from the filling point. i) from a make-up vessel or tank mounted in a position
higher than the top point of the system, and connected
Expansion Vessel through a non-return valve to the system on the
A diaphragm type expansion vessel to BS 4814: Pt 1. return side of the hot water cylinder or the return side
shall be fitted close to the inlet side of the pump. The of all heat emitters.
connecting pipework should not be less than 15 mm.
Pipework connecting the expansion vessel should not or
incorporate valves of any sort. Methods of supporting
the vessel are supplied by the vessel manufacturer.
ii) where access to a make-up vessel would be difficult
The nitrogen or air charge pressure of the expansion
by using the mains top up method or a remote
vessel shall not be less than the hydrostatic head,
automatic pressurisation and make-up unit as shown
(height of the top point of the system above the
in Figs. 7.
expansion vessel). To size the expansion vessel it is
first necessary to calculate the volume of water in the
Mains Connection
system in litres. The following volumes may be used as
There shall be no connection to the mains water supply
a conservative guide to calculating the system volume.
or to the water storage tank which supplies domestic hot
water even though a non-return valve, without the
Boiler Heat Exchanger: 2.1 litres
approval of the Local Water Authority.
Small Bore Pipework: 1 litre per kW of system
output
Filling Point
Micro Bore Pipework: 7 litres
The system shall be fitted with a filling point at low level
Steel Panel Radiators: 8 litres per kW of system
which incorporates a stop valve to BS 1010 and a double
output
check valve of an acepted type to be fitted in this order
Low Water Capacity Rads: 2 litres per kW of system
from the system mains, see Fig. 7.
output
Hot Water Cylinder: 2 litres

If the system is extended, the expansion vessel

volume may have to be increased unless provision has
been made for extension. Where a vessel of the
calculated size is not available, the next available
larger size should be used.

10 Installation Requirements Publication No. 5105703

 Water Level

Vent

Optional Optional
3 Port Zone
Valve Valves
Max. 30.5m (100ft)
Min. 305mm (1ft)

By-pass
balancing
valve

Top
of Heat Alternative By-pass arrangement using the
Exchanger Boiler Bathroom Radiator fitted with two locksheild valves
PRF0008A

Fig. 5

Vent Cylinder Make up

Vessel
Pressure Optional Optional
Gauge 3 Port Zone
Safety
Valve Valves
Valve

By-pass
balancing
Expansion valve
Vessel

Alternative By-pass arrangement using the

Boiler
PRF0009A

Bathroom Radiator fitted with two locksheild valves

Filling Point
Fig. 6

Two methods of filling a sealed

water system
Method 1 Method 2
Mains
Mains Topping-up Method Water
Cistern Filling Method
Supply
Note: This method of filling Note: Cistern to be supplied through a
(Service
a sealed system may only be temporary connection from a service
Pipe) Mains
used if acceptable to the Local pipe or cold water distributing pipe
Water
Water Undertaking
Supply
Overflow

Heating System Hose Union Cistern

PRF0010A

Double Stop Temporary Stop Valve Pressure Pump

Check Valve Hose reducing valve
Valve (if required)

Fig. 7

Publication No. 5105703 Installation Requirements 11

 Cylinder
By-pass using bathroom
radiator connected into
Gravity Circuit and fitted
with two lockshield valves
Min. to be installed when a
Circulating
Optional zone valve is fitted in
Head 1.2m Zone Valve Gravity Circuit
(4ft)

PRF0011A

Fig. 8

Circulation Pump Selection

Model Water Flow Rate Boiler Resistance

The resistance through the heat exchanger with Disc Without Disc
when operating with a water flow rate Litres/sec gal/min KN/m² in wg KN/m² in wg
producing an 11°C temperature rise at
maximum boiler output are shown in the 40 .25 3.34 2.7 11.0 .75 3.0
table. If other controls such as three position
50 .32 4.17 4.0 16.0 1.25 5.0
valves are used in the system, the resistance
60 .38 5.0 5.7 23.0 1.75 7.0
through them, quoted in their manufacturers
80 .51 6.67 10.5 42.0 3.0 12.0
literature must be taken into account. The
pump may be fitted on either the flow or
return and MUST be wired directly to the
boiler terminal block. It must be fitted with kN/m² in wg
With
two isolating valves which are positioned as Injector
close to the pump as possible. Closing of 10.5 42 Disc
any valve must always leave the open vent
unobstructed.
9.0 36

7.5 30

6.0 24

4.5 18

3.0 12 Without
Injector
Disc
1.5 6
PRF0007A

Imp. Gall/min. 1 2 3 4 5 6 7
Litres/sec .076 .152 .227 .303 .379 .455 .53

12 Installation Requirements Publication No. 5105703

 2. Installation
These instructions assume you have decided on where
the boiler will be located and the type of flue system to be
used. Boiler Pack contains:
Boiler, Literature Pack, Auxiliary pack containing boiler mounting bracket,
gas service cock and accessory packs.
2.1. Carefully unpack the boiler and flue.
Horizontal Flue System Pack contains:
Air/Flue duct assembly - length as orderd, flue elbow extension, flue
Do not discard any packaging until all the items are
terminal, flue sealing collar, rope sealing ring and two side infill panels.
accounted for.
Vertical Flue System Pack contains:
2.2. Fixing Template Air/Flue duct assembly, flue terminal, terminal cowl, vertical flue adaptor,
accessory pack and two side infill panels.

Place the template in proposed position ensuring it is

level, the minimum side clearances are automatically
allowed for. Top of boiler
reference marks
B
Rear Fluing:
B
Mark holes 'A', 'B', 'D', large flue outlet hole and side of B
boiler reference lines through slots 'C'.
B B
B C
Side Fluing: Side of A A
Mark holes 'A', 'D' and side of boiler reference lines boiler Holes
through slots 'C'. reference for Wall
marks Mounting
Brackets
Mark large flue outlet hole and holes 'B' using the thick Fold A A
lines on the template for minimum clearance at the rear Line
of the boiler and the thin dotted lines for maximum for LH
clearance. Flue
Outlet

PRF0012A
Note: Take into account the note within the boiler Fold
dimensions on Page 7. Line D
for RH
Flue
2.3. Boiler Mounting Plate Outlet Bottom of boiler Template
Fig. 9
Remove template and carefully cut flue outlet hole
through wall. If necessary, make good around the hole
to enable holes 'B' to be drilled.
Fixing
Wall Sealing Screw
Note: If using internal flue fitment kit refer to the Plug Collar (2 off)
Hole for
instructions supplied with the kit. Flue Outlet (2 off)

Drill holes 'A' using a 7 mm drill

Boiler
Drill holes 'B' and 'D' using a 5 mm drill Mounting
Bracket
Using wall plugs, screws and washers (accessory Side of Boiler Max. Rear
Ref. Mark Clearance
pack A) attach boiler mounting plate to the wall.
Ensure it is level and the correct way up, i.e. to provide Boiler
the clearance at the rear of the boiler allowed for when Mounting
Bracket
marking out using the template.
Min. Rear
Clearance
Wall
Insert wall plugs into holes 'B' (accessory pack B) and Plug
holes 'D' (accessory pack D). Plain (4 off)
2" No. 12
Screws (4 off) Washer
Insert flue sealing collar into wall and secure with (4 off)
PRF0013A

Cupwasher
screws provided, (accessory pack B). Make good the (4 off)
internal wall surface around flue sealing collar.
Fig. 10

Publication No. 5105703 Installation 13

 'X' 2.4. The Flue
'Y'
Side Flue

1. Measure from outside face of wall to the

side of boiler casing reference line (dimension
'x').
2. Take air/flue duct assembly and measuring
from the flanged end mark and cut the outer
duct and inner flue duct to dimension 'x' plus
PRF0014A 20 mm.

Ensure that both ducts are cut squarely.

Fig. 11 Note: Cutting length remains the same for

minimum or maximum clearance at the rear of
the boiler.

Rear Flue

1. Measure wall thickness (dimension 'y').

2. Take air/flue duct assembly and measuring
Inner from the flanged end mark and cut the outer
PRF0015B

Flue duct and inner flue duct to dimension 'y' plus

Duct 48 mm, or dimension 'y' plus 58 mm if boiler
mounting plate has been inverted.
40 to 50
Ensure that both ducts are cut squarely.
Rope Sealing
Discharge
Ring
Vanes 2.5. Air/Flue Duct Assembly
Air Duct
Terminal Note: During assembly the seam in the air duct
should be so arranged that when installed, the
seam in the duct will be uppermost.
Fig. 12
1. Slide rope sealing ring on to air duct.
2. Engage the terminal on to the ends of the
inner flue duct and press fully home.

Note: On 60 & 80 models there is a silicone seal

Tab Sealing on the inner edge of the terminal. This is to
Gasket prevent recirculation of flue products.

Air Duct 3. Engage four screws from accessory pack C

Flange into the pre-drilled holes in the terminal and
screw fully home.
Rope
These screws are self tapping on 60 & 80
Sealing
models. These will pierce the air duct and
Ring
secure the terminal to it.
On the 40 and 50 models it is necessary to
PRF0016A

Tab drill four pilot holes in the air duct.

4. Protect the duct where it is likely to come

into contact with mortar by using adhesive
Tape tape provided in accessory pack E.

Fig. 13

14 Installation Publication No. 5105703

 Door Flue Elbow Extension Flue Elbow

Hinge Brackets Flue Outlet

Fan Sealing Plate

Boiler Main
Assembly
Connector

Combustion Chamber Securing Screw

Front Panel Access Door

PRF0017A
Controls Cover Fig. 14

5. Insert the assembly into the wall sliding the rope Note: If side fluing, loosen the two brass securing
sealing ring along the air duct into the flue sealing nuts beneath the flue elbow outlet and remove the
collar. Bend the six tabs on the flue sealing collar other two. Tilt the flange and withdraw the elbow.
inwards to retain the rope sealing ring. Ensure air
duct flange studs do not obstruct lifting of boiler The boiler is supplied with the flue outlet sealing plate
onto mounting bracket. removed on one side. If another flue outlet direction is
required, remove the appropriate flue outlet sealing plate
2.6. Prepare the Boiler and transfer it to the left hand position.

The controls cover should have been removed when

unpacking the boiler, if not remove controls cover by Remove RH
LH Flue Outlet Securing Nuts Flue Outlet
opening the door covering the securing screw on the
Sealing Plate (4 off) Sealing Plate &
underside of the controls cover, see Fig. 14. Undo Removed fit to LH Side
securing screw, pull controls cover forward 10 mm,
lower to release from the four side fixings and pull
forward clear of the thermostat knob.

Remove door by undoing the two lower fixing screws

and lift door off the two upper hinge brackets.

Remove the screws securing the combustion chamber

front panel and remove panel.

Disconnect the fan supply leads from the connector

adjacent to the fan. Leaving in place the three screws
PRF0018A

identified with a red circle or adjacent ‘F’ mark in fan

plate. Remove the remaining screws securing the fan
mounting plate and remove the mounting plate
complete with fan.
Example of Right Hand Flue Outlet
Disconnect the two flexible tubes from the flue elbow.
Remove the four brass securing nuts and lift off the
flue elbow, taking care not to damage the gasket.
Fig. 15

Publication No. 5105703 Installation 15

 Air/Flue Duct 2.7. Install the Boiler
Assembly
Lift the boiler onto its mounting bracket.
Locate the studs on the air duct flange
through the boiler casing and secure using
four wing nuts (accessory pack F).

Wing
Nuts

PRF0019A
(4 off)

Fig. 16
Position boiler on its mounting bracket so
that the sides of the boiler line up with the
reference lines ‘C’ on the rear wall.

Undo the two screws securing the

transportation foot and discard foot. Vertical
alignment with rear wall can be corrected
using the adjustment screws at the rear of
the boiler.

Adjustment
Screw
PRF0020A

Remove
Transportation
Foot

Fig. 17
Rotate the left hand adjustment screw to
align one of the holes in the base plate with
PRF0021A

Leg hole ‘D’ in the wall. Working through the hole

in the leg, secure the base plate to the wall
using the screw from accessory pack D.

Make good the wall surface around the flue

terminal.

Fit optional terminal wall plate if required.

Securing
Screw

Fig. 18

16 Installation Publication No. 5105703

 When side fluing, slide the elbow extension
onto the elbow and ensure that it is pushed
Red or Pink Sensing Clear Sensing Tube
on fully. Engage the screw from accessory
Tube (connect to red indicator) (no kinks in either tube)
pack ‘C’ into the pre-drilled hole in the elbow
extension and screw fully home. The self
tapping screw will pierce the elbow and
secure the extension to the elbow.
Flue Extension
When rear fluing, the elbow extension should Red (required for side Securing Red
be discarded. Indicator flues only) Screw Indicator

Slide the flue elbow into the flue duct and

locate the flange over the studs on the
fluehood ensuring that the sealing gasket is
in place.

Secure the elbow to fluehood using the four

brass securing nuts.
Sensing Flue Sensing
Reconnect flexible tubes to elbow, ensure Tube Elbow Tube
they are not kinked. Connections Connections

Note: Red tube connects the front aluminium

tube in upper chamber to the lower connection Return
on elbow, each being identified with a red Thermostat Flow
ring. Bulb

Gasket & 4 Nuts

PRF0022A

Fig. 19

Publication No. 5105703 Installation 17

 22mm
Pumped
Return

Olive
28mm
Nut

28mm Gravity
Return

Injector
Disc
28mm
28mm

Pumped
Fig. 20 Olive Return
Gravity
Flow
Injector Disc
Pumped Gravity
Flow Return
PRF0023A

2.8. Connect System Pipework

Connect system pipework to the boiler, compression fittings should be used. Ensure that the flow and return pipes do not
rotate during tightening. The return pipe is marked with an identation, this should face towards the front of the boiler.

If however capillary fittings are used it is essential to temporarily remove the thermostat bulb from the flow pipe before
soldering.

A drain off tap should be installed close to the boiler if it is in a low point of the system.

On combined gravity hot water/pumped central heating installations the flow and return pipes for both the gravity hot water
circuit and pumped central heating circuit must be connected to tees fitted directly to the flow and return pipes on the boiler.

The gravity circuit should be installed in 28 mm copper pipe.

The injector disc (accessory pack H) must be positioned in the pumped return branch of the tee and the pipes connected
to the tees as illustrated in Fig. 20.

Connect the gas supply pipe to the inlet of the gas cock. Ensure that the gas cock is in a position where it can be easily
operated when the controls cover is removed.

18 Installation Publication No. 5105703

2.9. Set Overheat Thermostat Bulb
Position

Ensure that the system change-over switch

in the control box is correctly set e.g. for
GRAVITY DHW system or FULLY PUMPED
system. See Fig. 1.

If the boiler is to be used on a GRAVITY

PRF0025A
DHW system the bulb of the overheat Fully Pumped Gravity DHW
thermostat must be repositioned as shown System Position Position
in Fig. 21. To do this loosen the plastic
retaining screw and withdraw the thermostat
bulb from its pocket.
Fig. 21
Position the bulb as illustrated and secure it
by finger tightening the plastic screw. Do not
over-tighten.

2.10. Electrical Connections

The boiler and all external control circuit EXTERNAL ROOM AND/OR
wiring must be supplied from the same ELECTRICITY PROGRAMMER CYLINDER
SUPPLY THERMOSTAT
single isolating switch or plug and socket,
and should be fused at 3A.
4 OR 6 Core 4 OR 5 Core
Care must be taken to ensure that all wiring
to the boiler is kept clear of sharp edges and EXTERNAL 3 Core
ISOLATOR JUNCTION BOX
hot surfaces. SWITCH

The boiler terminal block which is situated in 5 OR 8 Core 4 Core

the control box is not designed to accept

PRF0024A
wiring from all the on site controls and CONTROL
therefore the installer will usually need to VALVES BOILER PUMP
ETC. 3 Core
incorporate a suitable junction box. This
may not be required if a Potterton Electronic
Programmer is used as this incorporates a
junction box. The principle of wiring is shown Fig. 22
in Fig. 22.

Remove control box securing screw and

lower the control box to gain access to the
boiler terminal block.
PRF0026A

Securing Screw

Fig. 23

Publication No. 5105703 Installation 19

 Following the pump manufacturer’s instructions
connect the pump supply wires to terminals
marked PUMP L, N, on the boiler terminal
block. Route the cable through the plastic bush
in the rear of the control box as illustrated in
Fig. 24 and secure, using the cable clamp.

PRF0030A
Route a four core cable through the plastic bush
in the rear of the control box and the cable clamp
as illustrated in Fig. 24 and connect it to the
boiler input terminals as follows:-

Fully Pumped Systems.

Test Socket
Permanent live to terminal marked MAINS ‘L’.
Gas Control Valve Neutral to terminal marked MAINS ‘N’.
Supply Lead Earth to terminal marked ' ' adjacent to cable
clamp. See Note.
Switched live from external controls to terminal
marked MAINS’ SwL’.
PUMP MAINS
If there are no external controls fitted connect
the SwL terminal to permanent live in the
L N Swl N L
junction box.

Gravity Domestic Hot Water/Pumped Central

Heating Systems.
Switched live from external gravity domestic
hot water control circuit to terminal marked
Fig. 24
MAINS ‘SwL’.
Switched live from external pumped central
heating control circuit to terminal marked MAINS
‘L’.
Neutral to terminal marked MAINS ‘N’.
Earth to terminal marked ‘ ’ adjacent to cable
clamp. See Note.
If there are no external controls fitted connect
the SwL terminal to permanent live in the
junction box.

Note: Ensure that the earth conductor is longer

than the L, N & SwL from the point of anchorage,
so that the current carrying conductors become
PRF0027A

taut before the earth conductor if cable is pulled

out of the cable clamp.

When the wiring has been completed close the

control box and replace the securing screw.

2.11. Fitting Side Infill Panels

If required, the gap between the casing sides and rear wall can be closed
off using the infill panels supplied.

Ensure the casing surface is fully clean and dry. Remove the protective
backing paper from the adhesive strip on the infill panel, carefully align
and press into place, applying firm even pressure down the full length of
contact area between panel and case. It conditions are near freezing, the
boiler case should be warmed prior to application of the infill panel.
Fig. 25

20 Installation Publication No. 5105703

 3. Commissioning
Important Important
The commissioning and boiler adjustment must When checking for gas soundness open
only be carried out by a suitably qualified all windows and doors in the room.
personnel. Potterton offer this service on a Extinguish all naked lights, cigarettes, pipes, etc.
chargeable basis.

Open Vented Systems

Gas will flow to the pilot only. It will not be ignited as the
Remove the pump and flush out the system thoroughly ignition system is de-energised.
with cold water. Refit the pump. Fill and vent the system. Using a leak detection fluid, check pilot unions for gas
Examine for leaks. soundness.

Sealed Systems Turn off the external electricity supply and gas service
cock.
Note: The system can be filled using a sealed system
filler pump with a break tank or by any other method Remove gas control valve plug from the test socket and
approved by the Local Water Authority. Refer to ‘The refit the plug into the socket on the left hand side of the
System’, Section 1.9, Page 9 in these instructions, also control box see Fig. 24.
BS6798: 1987.
Refit the combustion chamber front panel.
Remove pump and flush out the system thoroughly with
cold water. Refit the pump. Fill and vent the system until Fit the case door into position by lifting it onto the top
the pressure gauge registers 1.5 bar (21.5 Ib/in²). hinge brackets and secure it with the lower two fixing
Examine for leaks. screws. ENSURE THAT A GOOD SEAL IS OBTAINED

IMPORTANT: The pressure relief valve is factory tested Remove the temporary label from the front of the casing,
and does not need testing during the commissioning of having checked compliance with the information it
the boiler. It must not be used to reduce system contains.
pressure as it may cause debris in the system to foul the
valve. First Lighting

All Systems Warning: Before lighting the boiler, ensure that the
CASE DOOR HAS BEEN CORRECTLY FITTED and
Refit the fan assembly and reconnect the fan supply that the sealing strip fitted to the case door is forming a
leads, (polarity of the fan leads is not important). tight seal with the main boiler casing. Before proceeding
to light the boiler, check that the external electricity
The whole of the gas installation including the meter supply to the boiler is switched off and that the boiler
should be inspected and tested for soundness and thermostat is in the ‘0’ position.
purged in accordance with the recommendations of
BS6891. Turn on the gas service cock, ensure that the pump and
radiator isolating valves are open, ensure that the time
Test pilot unions for gas soundness as follows: Turn control, if fitted is in an on condition, and that the room
boiler thermostat to the ‘0’ position. and/or cylinder thermostats, where fitted are set to high
temperatures.
Unplug the gas control valve supply lead from the
control box and plug it into the test socket adjacent to Switch on the external electricity supply to the boiler.
the boiler thermostat knob, see Fig. 24.
In the event of an electrical fault after installation of the
Turn on gas at the gas service cock. appliance, preliminary electrical system checks must
be carried out i.e.:-
Ensure that the time control if fitted is in an ON
condition, and that the room and/or cylinder thermostats A. Earth Continuity
where fitted are set to high temperatures. B. Short Circuit
C. Polarity
Switch on the external electricity supply to the boiler. D. Resistance to Earth

Publication No. 5105703 Commissioning 21

 Refer to Fault Finding Chart Fig. 31 Pilot Burner

Turn the boiler thermostat on and to a high setting and The pilot is pre-set and no adjustment is required. The
after a period of time the main burner will light, this can pilot flame envelope should cover the electrode tip and
be observed through the sight glass in the front cover of spark earthing strip, see Fig. 30. If the pilot flame is not
the boiler. The time period can vary upwards of 45 as illustrated, remove and clean the pilot as described
seconds, depending on the amount of air in the pipework. in the Servicing Instructions Section 4.3, Pilot Burner,
Page 26.
Test for gas soundness around the boiler components
using leak detection fluid. Boiler Thermostat

Turn the boiler thermostat to ‘0’. Note: There could be a At its minimum and maximum settings, the thermostat
delay in lighting if the control knob is switched on and off should control the water flow temperature at approximately
and then on again rapidly. 55 °C - 82 °C (130 °F - 180 °F).

Setting and Checking of Controls The thermostat has been calibrated by the makers and
no attempt should be made to re-calibrate it on site. Turn
With the controls cover removed. the thermostat to the ‘0’ position and check that the main
burner shuts down.
Fit a pressure gauge to the pressure test nipple in burner
supply pipe. See Fig. 1. Gravity Hot Water/Pump Over-Run Thermostat

Turn on the boiler thermostat and ensure that the main The function of this thermostat is determined by the
burner is alight. Check that the burner pressure is in position in which the GRAVITY/FULLY PUMPED
accordance with values stated on the Data Badge. SYSTEM selection switch is set. The thermostat is pre-
set and no adjustment is possible.
The gas valve is factory set, but if adjustment is required
follow section 4.8. On the FULLY PUMPED switch position it will operate
as a pump over-run thermostat and will keep the pump
With the burner set to its correct pressure, the firing rate running after the boiler has shut down, as long as the
given in Technical Data should also be obtained and water temperature within the boiler is above approximately
this should be checked by meter reading at least 10 80 °C.
minutes after the main burner has been lit.
On the GRAVITY switch position it will operate in series
Shut down the boiler, remove the pressure gauge and with the boiler thermostat when only the gravity domestic
refit the screw in the test nipple ensuring that a tight seal hot water circuit is in operation.
is made.
It will over-ride the boiler thermostat when the water
Refit the controls cover. temperature within the boiler is above 80 °C.

Relight the boiler and heat the system to maximum. Overheat Thermostat
Check for water leaks, turn the boiler off, drain the
system whilst hot. The overheat thermostat is pre-set and no adjustment is
possible. It will require manually resetting if an overheat
Refill the system and on sealed systems adjust to the condition occurs. Access to the reset button is through
correct cold fill pressure. Set the pressure gauge pointer a hole in the underside of the controls cover, see Fig. 1.
to the system design pressure.
Other Boiler Controls
If a by-pass circuit is fitted the by-pass valve should be
adjusted with the boiler operating under minimum load All boiler mounted controls are designed so that if any
conditions to maintain sufficient water flow through the fault should occur they will fail safe. No further setting
boiler to ensure that the overheat thermostat does not or checking is necessary.
operate under normal operating conditions.

22 Commissioning Publication No. 5105703

 Pilot Screw Spacer
(For test
purposes only)

PRF0028A

Burner Pressure
Seals
Adjusting Screw

Fig. 26
External Controls

Check that any other external control connected in the

system, such as clocks and thermostats, control the
boiler as required.

User’s Instructions

A User’s Instructions leaflet is provided with this boiler

but the householder must have the operation of the
boiler and system explained by the Installer.

The householder must also be advised of the importance

of annual servicing and of the precautions necessary to
prevent damage to the system and building, in the event
of the system remaining out of commission in frost
conditions.

Finally, complete the Benchmark Log Book and hand

over all instructions.

Publication No. 5105703 Commissioning 23

 Central Heating Switched
Live on Combined Gravity
D.H.W. Pumped C.H. Systems Gravity/Fully
Pumped System
Selection Switch
Permanent Live on L Gravity Hot Water (Shown in Fully
Fully Pumped Systems Red or Pump Over Run Pumped Position) Pump
Thermostat L N

Red
Black
Switched Live on 4 NO Pump
White
Fully Pumped Systems Brown 3
2 C Blue Boiler Thermostat
Domestic Hot Water Switched SwL NC
Live on Combined Gravity
D.H.W. Pumped C.H. Systems
Brown

Brown White
N
Blue
Brown

Brown White
T1
Blue GV2
Gas
Overheat T2
Control
Thermostat Black Valve
S1 S2
Blue GV1
Blue T3

Electronic Orange (NO)

T4
Control (NC) Air
White 1 2 Pressure
T5
Switch
3
Test Socket Brown (C)
T6

Red
T7

Red Fan
T8
N
Blue PRF0029A

Fig. 27

R
R

BR
B BR
R
W
BR

BR R

BR B
BR
BR

G/Y
BK BR
Honeywell Gas Valve B
B
W W OR
BK W
W BR R

B R

G/Y
BR
B W G/Y
BK
G/Y G/Y

BK BK
B G/Y
W B
Colour Key
R
BR = Brown
BK = Black B BR Pump Mains
B = Blue
W = White L N SwL N L
PRF0033A

OR = Orange
G/Y = Green/ Yellow

L N SwL N L
This Appliance must be Earthed

Installer Terminal (6 way)

Fig. 28

24 Commissioning Publication No. 5105703

 4. To Service the Boiler & Component Replacement
Remember to fill in the Benchmark Log Book. Regular the front door from the boiler, most components are exposed.
skilled servicing and cleaning of the appliance is essential Remove the front of the combustion chamber to gain
to ensure continued safe and efficient operation. The access to the main and pilot burner and the ignition
frequency of cleaning will depend upon the particular electrode. Removal of the fan and its mounting plate
installation conditions, and the use to which the appliance exposes the flue system, i.e. the flue elbow and fluehood.
is put, but in general, once per year should be adequate. These must be removed to gain access to the flueways in
the heat exchanger for cleaning.
It is the law that all gas appliances are installed and
serviced by competent persons as stated in Gas Safety The following notes apply to the boiler and its controls but
(installation and Use) Regulations 1998. it should be remembered that attention must also be paid to
the heating circuit itself including radiator valves,
For Health and Safety information see page 4. thermostats, the time control and the expansion and feed
water system. It is advisable to clean the boiler immediately
Electrical installation and servicing should be carried out by after the end of the heating season.
a competent person in accordance with the I.E.E. Wiring
Regulations. In all cases prior to servicing, light up the boiler and check
that the pilot and main burners have a clean, even flame and
Servicing is best arranged by a contract placed with that the gas rate and main burner pressure are correctly set.
Potterton and further details are available from Service If the pilot flame is satisfactory, no further servicing of the
Enquires - see back page. pilot burner is necessary and the information given in ‘4.3.
Pilot Burner’ can be ignored.
The boiler DATA PLATE and WIRING DIAGRAM are
attached to the inside of the controls cover. The boiler Warning: Before the start of any servicing work, switch off
CODE NUMBER which should be quoted when ordering at the external electricity supply by disconnecting the
spares or requesting information is on the front of the control supply plug at the socket or switching off the external
box. See Fig. 1. isolating switch. Turn off the gas service cock.

All parts likely to require servicing are readily accessible. Note: After completing any servicing or replacement of
By removing the cover from the boiler controls and removing components check for gas soundness and carry out
functional checks.
PRF0032A

Gas
Control
Valve Plug
Burner
Securing
Screws

Gas Control
Valve/Support
Bracket Screw
Fig. 29

Publication No. 5105703 To Service the Boiler & Component Replacement 25

4.1 Preparing the Boiler for Servicing 4.2 Heat Exchanger

Note: Boilers with side or rear flues have a flue elbow A. Working from above and below the heat exchanger
fitted to the fluehood. use a suitable brush and remove all deposits from
between the fins.
The elbow is replaced by an adapter on vertically flued Slide vertical flue adapter into flue duct.
boilers.
B. Refit the fluehood, ensuring that the rope seal is
A. Remove controls cover by opening the door covering undamaged and that a GOOD SEAL is made with the
the securing screw on the underside of the controls heat exchanger. Fully tighten the four nuts.
cover, see Fig. 14. Undo securing screw, pull controls
cover forward 10 mm, lower it to release it from its C. Slide the flue elbow into the flue duct or lower flue
four side fixings and pull forward clear of the adapter and secure to the fluehood using four nuts.
thermostat knob. Ensure that the gasket between the fluehood and
elbow or adapter is undamaged and a good seal is
B. Remove door by undoing the lower fixing screws and obtained.
lift door off the two upper hinge brackets.
D. Reconnect flexible tubes to elbow or adapter.
C. Remove screws securing the combustion chamber
front panel and remove panel. Note: Red tube connects the front aluminium tube in
the upper chamber to the lower connection on elbow
D. Disconnect the fan supply leads from the connector or adapter, each being identified with a red ring.
adjacent to the fan.
4.3 Pilot Burner
E. Remove the screws securing the fan mounting plate
leaving in place the three screws identified with a red The following operations are only necessary if the pilot
circle or adjacent ‘F’ mark in fan plate. Remove flame is distorted or the wrong size, i.e. too small.
mounting plate complete with fan.
A. Check that the pilot screw Fig. 26, is fully open (turn
F. Disconnect the two flexible tubes from the flue elbow anti-clockwise).
or adapter.
B. Unscrew the aluminium pilot tube from the pilot
G. Loosen the two brass securing nuts beneath the flue assembly. Take care not to damage the electrode.
elbow outlet and remove the other two. Tilt the flange
and withdraw the elbow. Take care not to damage the C. Unscrew the two hexagonal head screws securing
gasket. On vertically flued boilers remove the four the pilot (and shield on 80) to the main burner and
brass nuts and slide the vertical flue adapter up into remove the pilot assembly, be careful that the pilot
the flue duct. injector does not fall out during this operation.

H. Unscrew the four nuts and lift off the fluehood taking D. Lightly brush the pilot and its shield to remove any
care not to damage the rope seal. deposits. Remove the pilot injector and clean its
Lower and lift out vertical flue adapter. orifice or replace.

I. Undo the union on the gas service cock outlet. Note: Do not use a wire brush or pin to clean injector.

J. Unplug the electrical supply leads for the gas control E. Gently clean any deposits from the electrode.
valve from the control box. See Fig. 29.
F. Refit the pilot injector to the pilot burner and assemble
K. Remove the screw securing the gas control valve to the pilot to the aluminium tube.
its support bracket. See Fig. 29.
G. Secure the pilot assembly to the main burner using
L. Disconnect electrode lead from electrode. two hexagonal screws.

M. Remove two screws securing the burner assembly H. Fully tighten the union nut connecting the aluminium
to the bottom of the boiler case and lift out the burner tube to the pilot. Check for gas soundness at this
and gas control assembly. joint by following the procedure described in the
commissioning section of these instructions, Page
21.

I. Ensure that the spark gap is as illustrated in Fig. 30.

26 To Service the Boiler & Component Replacement Publication No. 5105703

 F. Reconnect gas supply at gas service cock and turn
on gas.
Spark Gap
G. Refit the combustion chamber front panel.
2.5 - 4.0mm
4.6 Fan

A. Carefully clean any deposits from around the fan

PRF0031A
motor and its supports.

B. Very gently clean the fan impellor taking care not to

damage the aluminium impellor or dislodge its balance
weights.
Fig. 30
C. Replace the fan and its mounting plate.
Ensure that the securing screws are fully tightened
as an air tight seal must be obtained between the fan
Pilot Filter assembly and the main boiler casing.
The pilot burner is protected from blockage by a pilot
filter situated within the gas control valve. The filter is D. Reconnect the fan supply leads (polarity is not
large and designed to last the life of the gas control valve important).
under normal operating conditions, it is therefore unlikely
to need replacing. However in the event of pilot filter 4.7 Case Seal
blockage being suspected the complete control valve
should be replaced. Check the case door seal. Replace if damaged. The seal
is simply pressed into the channel around the door.

4.4 Combustion Chamber Insulation Re-commission

A. Check the combustion chamber insulation for damage. Follow the full commissioning procedure as detailed in
If damaged replace as described under replacement. the Commissioning section of these instructions page
21.

4.5 Main Burner Other Boiler Mounted Units

A. Lightly brush any deposits from the top of each blade No further servicing is required on any other boiler
and ensure there is no fluff in the entry of the burner mounted units. Repair is by replacement.
venturi. If on re-assembly the burner flame picture is
incorrect or the correct gas rate or burner pressure Fault Finding
cannot be obtained, remove the burner and gas
control assembly and thoroughly clean the burner. Refer to Fault Finding Chart (page 32) and Wiring
Clean or replace the injector. In the event of the Diagrams (page 24).
above procedures not rectifying the flame appearance,
disconnect the burner from the gas control valve at
the flanged connection and replace the burner and
injector.

B. Refit the burner and gas control valve assembly into

the boiler, ensuring that the locating pin on the rear
of burner engages correctly into the rear support
bracket. Make sure that the sealing gasket is in
place and undamaged between the burner flange and
the case. Secure the assembly with two screws.

C. Refit the screw securing the gas control valve to the

support bracket.

D. Reconnect electrode lead to electrode.

E. Plug gas control valve supply leads into control box.

Publication No. 5105703 To Service the Boiler & Component Replacement 27

Removal/Replacement of Boiler Mounted Units 6. Follow the full commissioning procedure as detailed
in the Commissioning section of these instructions
4.8 Gas Control Valve on page 21.

This operation is most easily carried out by first removing 4.10 Main Burner
the burner and gas control valve assembly as follows:-
1. Switch off the external electricity supply by
1. Switch off the external electricity supply by disconnecting the plug at the socket or switching off
disconnecting the plug at the socket or switching off the external isolating switch.
the external isolating switch.
2. Remove controls cover, case door and combustion
2. Remove controls cover, case door and combustion chamber front panel as described in 4.1.’Preparing
chamber front panel as described in 4.1.’Preparing the Boiler for Servicing’, operations A, B and C.
the Boiler for Servicing’, operations A, B and C.
3. Remove the burner and gas control assembly as
3. Remove the burner and gas control assembly as described in 4.1.’Preparing the Boiler for Servicing’,
described in 4.1. ‘Preparing the Boiler for Servicing’, operations I, J, K, L and M.
operations I, J, K, L and M.
4. Unscrew the union nuts connecting the pilot supply
4. Disconnect the electrical supply wires from the gas pipe to the pilot and gas control valve. Take care not
control valve noting their position. See Figs. 27 & 28. to damage the electrode and be careful that the pilot
injector does not fall out during this operation.
5. Unscrew the union connecting the pilot supply pipe
to the gas control valve. Remove sealing grommet and withdraw the pilot tube
through the hole in the burner mounting flange.
6. Separate the gas control valve from the flanges at
the inlet and outlet ports by removing the securing 5. Separate the burner from the gas control valve at the
screws. flanged connection by removing the four securing
screws.
Note: A spacer is used between the valve outlet and
the burner flange, requiring the use of two seals at Note: A spacer is used between the valve outlet and
this point. See Fig. 26. the burner flange, requiring the use of two seals at
this point. See Fig. 26.
7. Use new seals on re-assembly.
6. Unscrew the pilot, main burner injector and pressure
8. Replacement is the reverse of removal. test nipple from the burner.

9. Check that the burner pressure is in accordance with 7. Use new sealing gaskets on re-assembly.
the information on the data badge. If adjustment is
required, turn the pressure adjusting screw anti- 8. Replacement is the reverse of removal.
clockwise to increase pressure or clockwise to
decrease. 9. Follow the full commissioning procedure as detailed
in the Commissioning section of these instructions
4.9 Fan on page 21.

1. Switch off the external electricity supply by 4.11 Pilot/Ignition Electrode

disconnecting the plug at the socket or switching off
the external isolating switch. 1. Switch off the external electricity supply by
disconnecting the plug at the socket or switching off
2. Remove controls cover and case door as described the external isolating switch.
in 4.1.’Preparing the Boiler for Servicing’, operations
A and B. 2. Remove controls cover, case door and combustion
chamber front panel as described in 4.1.’Preparing
3. Disconnect the fan supply leads from the connnector the Boiler for Servicing’, operations A, B and C.
adjacent to the fan.
3. Disconnect the electrode lead from electrode.
4. Remove the screws securing the fan to the mounting
plate and remove fan. 4. Unscrew the aluminium pilot tube from the pilot
assembly. Take care not to damage the electrode.
5. Replacement is the reverse of removal.

28 To Service the Boiler & Component Replacement Publication No. 5105703

 5. Unscrew the two hexagonal head screws securing
the pilot (and shield on 80) to the main burner and 4.13 Fuse 1 amp
remove the pilot assembly, be careful that the pilot
injector does not fall out during this operation. 4. The fuse is located on the electronic control and can
Unscrew electrode retaining nut and withdraw the be replaced by lifting it from its holder.
electrode. 5. Replacement is the reverse of removal. Refer to
Figs. 27 & 28.
6. Replacement is the reverse of removal. On
re-assembly ensure that the spark gap is as illustrated 4.14 Electronic Control
in Fig. 30.
4. Disconnect six way plug, two way plug and electrode
7. Follow the full commissioning procedure as detailed lead from the electronic control. Refer to Figs. 27 &
in the Commissioning section of these instruction 28.
on page 21.
Disconnect the flying leads of the electronic control
4.12 Combustion Chamber Insulation as follows:-

1. Switch off the external electricity supply by • white wire from terminal C (3) of the control
disconnecting the plug at the socket or switching off thermostat
the external isolating switch. • white wire from terminal NC (2) of the control
thermostat
2. Remove main burner as described in 4.1 ‘Preparing • brown wire from overheat thermostat
the Boiler for Servicing’, operations A, B, C, I, J, K, • blue wire from boiler terminal block connection N
L, M. • green/yellow wire from earth post

3. Bend back retaining tabs and replace insulation. It is 5. Release the control by lifting it from the four retaining
necessary to first remove the side insulation when lugs.
replacing the rear.
6. Remove electronic control.
4. Replacement is the reverse of removal.
7. Replacement is the reverse of removal.
5. Follow the full commissioning procedure as detailed
in the Commissioning section of these instructions 8. Follow the full commissioning procedure as detailed
on page 21. in the Commissioning section of these instructions
on page 21.
4.13 Fuse, 4.14 Electronic Control, 4.15 Pressure Switch,
4.16 Overheat Thermostat, 4.17 Boiler Thermostat, 4.18 4.15 Pressure Switch
Gravity HW/Pump Overrun Thermostat, 4.19 Heat
Exchanger Pipe Seal 4. Remove the screw securing the pressure switch to
the bracket in the control box. Lift pressure switch
Note: 4.13, 4.14 & 4.15 are on this page. 4.16, 4.17, from bracket.
4.18 & 4.19 are on page 30.
5. Disconnect the two plastic tubes.
The following initial operations 1-3 are necessary to
remove and replace any of the above items. Note: the red tube is connected to the pressure
switch connection identified with a red ring, or adjacent
1. Switch off the external electricity supply by red spot.
disconnecting the plug at the socket or switching off
the external isolating switch. 6. Disconnect the three electrical leads, white wire from
terminal No. 1 or NC, orange from terminal No. 2 or
2. Remove controls cover by opening the door covering NO and brown from terminal No. 3 or C. Refer to Figs
the securing screw on the underside of the controls 27 & 28.
cover see Fig. 14. Undo securing screw, pull controls
cover forward 10 mm, lower it to release it from its 7. Replacement is the reverse of removal. Ensure that
four side fixings and pull forward clear of the the plastic tubes are not kinked on re-assembly.
thermostat knob.
8. Follow the full commissioning procedure as detailed
3. Remove control box securing screw and lower control in the Commissioning section of these instructions
box. on page 21.

Publication No. 5105703 To Service the Boiler & Component Replacement 29

4.16 Overheat Thermostat 13.Remove the split grommet in the base of the boiler
and the split grommet in the fan chamber. Feed the
4. Remove door by undoing the two lower fixing screws capillary and bulb through the holes.
and lifting door off the two upper hinge brackets.
14.Replacement is the reverse of removal. The bulb of
5. Disconnect the two push on electrical connections the new thermostat should be coated with heat
from the overheat thermostat terminals. conducting paste. Ensure the rubber grommets in
the base of the boiler and the fan chamber make a
6. Remove the nut securing the overheat thermostat to good seal around the capillary.
its mounting bracket.
15.Ensure that the capillary is secure in the clips
7. Noting the route taken by the capillary, loosen the provided.
plastic screw retaining the thermostat bulb and
withdraw bulb from its pocket. Remove the split Follow the full commissioning procedure as
grommet in the base of the boiler, feed the thermostat detailed in the Commissioning section of these
capillary and bulb through the hole. instructions on page 21.

8. Replacement is the reverse of removal. Ensure the 4.18 Gravity Hot Water/Pump Overrun Thermostat
rubber grommet in the base of the boiler makes a
good seal around the capillary. Ensure that the 4. Remove door by undoing the lower fixing screws and
capillary is secure in the clips provided. Refer to Fig. lifting door off the two upper hinge brackets.
21.
5. Disconnect the electrical connections as follows:
9. Follow the full commissioning procedure as detailed
in the Commissioning section of these instructions 2 red wires from terminal NO (4)
on page 21. 2 brown wires from terminal NC (2)
1 white and 1 blue wire from terminal C (3)
4.17 Boiler Thermostat (These are the larger numbers marked on the
thermostat, ignore the smaller numbers).
4. Remove door by undoing the two lower fixing screws
and lifting door off the two upper hinge brackets. 6. Remove the screws securing the thermostat to the
control box.
5. Disconnect the fan supply leads from the connector
adjacent to the fan. 7. Remove the split pin retaining the thermostat bulb in
the pocket and withdraw the bulb.
6. Remove the screws securing the fan mounting plate,
leaving in place the three screws circled red (or with 8. Remove the split grommet in the base of the boiler.
adjacent 'F' mark), and remove the plate complete Feed the capillary and bulb through the hole.
with fan.
9. Replacement is the reverse of removal. The bulb of
7. Disconnect the electrical connections as follows:- the new thermostat should be coated with heat
conducting paste. Ensure the rubber grommet makes
White from terminal C(3). White from NC(2) - Refer to a good seal around the capillary.
Figs. 27 & 28.
10.Ensure that the capillary is secure in the clips
8. Pull off the outer thermostat knob. provided. Follow the full commissioning procedure
as detailed in the Commissioning section of these
9. Remove inner thermostat post by undoing the two instructions on page 21.
securing screws.
4.19 Heat Exchanger Pipe Seal
10.Remove the nut securing the thermostat to the
control box. 4. Remove door and fan mounting plate as described in
4.17, sections 4, 5 & 6.
11.If the boiler is fitted with a left hand flue, remove the
flue elbow as described in Section 4.1, Preparing the 5. Loosen pipe nut, lift pipe and remove seal.
Boiler for Servicing, operations F & G.
6. The return pipe is marked with an indentation, this
12.Remove the clip securing the thermostat bulb to the should face towards the front of the boiler.
flow pipe.

30 To Service the Boiler & Component Replacement Publication No. 5105703

 Intentional Blank

Publication No. 5105703 Intentional Blank 31

 Fig. 31
Flame Supervision Testing Test Procedure For Measuring Flame Current
Start

32 Fault Finding
With the boiler running, turn off at the boiler thermostat. Disconnect the white wire from GV2 on gas control valve and
Temporarily restrict the pilot gas supply by fully screwing in the connect it via a suitable test switch to neutral as shown. Set
All service on gas valve pilot screw clockwise. Turn on at the boiler thermostat: test switch to OFF. Insert an approved ammeter in series
a spark will be present, indicating GV2 is electrically disconnected, with the spark electrode.
Ensure system and the boiler will not light. Now reinstate the pilot supply (three Turn ON the electricity supply and restart the boiler.
change-over
switch in control
complete anti-clockwise turns); pilot and main boiler will light in the NOTE: The pilot will light but not the main burner as GV2 is
box is set normal manner. disconnected.
correctly Test When the pilot is established set the test switch to ON. This
Switch will stop the spark and allow a steady flame current to be
White wire N
Call for heat disconnected measured.
from GV2
Fully pumped
system only
Check full operational Does fan Yes Does fan run Yes Is electrode Yes Does Pilot Yes Does Pilot Yes Does main Yes Does boiler Yes Following a Yes Boiler Yes
operate? without sparking? burner light? cycle off and run period at operate Boiler
sequence to ensure light? remain lit?
cycling on/off on under maximum without operating
that the boiler and No No No No No satisfactory
pump overrun control of temperature, tripping the
No
5. Fault Finding Guide

thermostat Ensure there is Is case door Yes the boiler does pump overheat
leaking? Is there thermostat continue to thermostat?
are operating correctly 240 +
_ 10%
240v +_ 10% Yes when system operate after
between L & N No Yes Does spark
between is up to boiler No
and 240v +
_ 10% stop?
T2 & T3 on temperature. thermostat
between Swl Are sparks Yes electronic No See note operates?
and N. occurring
control? If gas is not
Fully pumped elsewhere?
flowing out No No
system. No Are all
Yes Has overheat No Check case door of pilot, check Check
Check pump is valves
thermostat seal and replace jet is not solenoid Yes
operating and open and
operated? if damaged. Fully blocked & pilot GV2 replace
water is water
tighten two lower screw on gas Switch off if necessary
circulating No Is there circulating
securing screws. valve open external
correctly. 240v +_ 10% correctly
Check fuse on, electricity
Gravity DHW between T2
electronic supply and
system ensure and T4
control follow the
overheat on electrode test Yes
thermostat Replace control procedure
bulb is located electronic Replace
Check all No described
correctly control electronic
appliances above.
see Fig. 21. control
wiring and Ensure air Is there
Press overheat
electrical pressure more than
reset button.
components. tubes are 1.5µA
not kinked recorded?
or blocked Check and/
and are or replace No
_
Is there 240v + correctly electrode
10% between fitted. lead
Yes T6 & T2 on
electronic control?
No Check Check that Replace Replace Replace
Check and/ Replace
Replace Check and/or or replace solenoid pilot is not electronic appropriate pump overheat
fan replace air air pressure GV1 replace partially control thermostat. overrun thermostat
pressure switch switch if necessary blocked. See note thermostat

PRF0034A
NOTE: When pumped central heating is
in operation the boiler is controlled by the
main boiler thermostat.
When only a gravity hot water circuit is in
operation the boiler is controlled by the
Fault Finding Chart main boiler thermostat when set at No.4
or below. At setting above No.4 the
temperature is limited by the operation
of the gravity control thermostat.

Publication No. 5105703

 6. Optional Extras
Optional Extras

Internal Fitment Kit, which is suitable for a maximum

wall thickness of 510 mm and where access to the
outside wall is impracticable.

Pump Cover Kits, located on top of the boiler and

designed to conceal the pump, and/or any motorised
valves installed above the boiler. Note: The pump
cannot be fitted above the boiler if using a vertical flue
kit.

Terminal Wall Plate, where necessary can be fitted to

the outside wall face to improve the appearance, after
making good around the flue terminal.

Terminal Guard, to be used when the terminal is fitted

less than 2 m above a balcony, above ground or above
a flat roof to which people have access.

Installation Instructions are supplied as necessary with

the kits

Kit Models & Part Numbers

40 50 60 80

Standard Flue System 5105761 5105761 225541 225541

2 Metre Flue System 225543 225543 225544 225544
Vertical Flue System 5106368 5106369 5106370 5106371
Terminal Wall Plate 212306 212306 212280 212280
Terminal Guard 205792 205792 205792 205792
Internal Fitment Kit 225183 225183 225184 225184
Pump Cover Kit (6in) 225418 225418 225418 225418
Pump Cover Kit (7in - 12in) 225419 225419 225419 225419
Pump Cover Kit (13in - 18in) 225420 225420 225420 225420
Pump Cover Kit (19in - 24in) 225421 225421 225421 225421

Publication No. 5105703 Optional Extras 33

 7. Short List Of Spare Parts

11
1 8

6
2
4
3 15 7
12

16 21
21
9
18
10

15 19
13

PRF0035A
17

Fig. 32

34 Short List Spare Parts Publication No. 5105703

 Drg. Ref. G.C. No. Description Qty Part No.

1 382 453 Pilot and Electrode Assembly 1 212259

Includes items 2 and 4
2 381 656 Pilot Injector 1 402915
3 357 932 Shear Off Union 1 402492
4 382 448 Electrode 1 402925
6 337 369 Electrode Lead 1 407697
7 248 147 Control Thermostat K36 L1014 1 907729
8 395 796 Gas Control Valve - Honeywell 1 907704
Includes item 10
9 337 480 Gas Manifold Gasket 1 212105
10 337 467 Gas Manifold 'O' Ring 1 401637
11 337 431 Gravity DHW/Pump Overrun Thermostat 1 404501
CL8 P1501
12 337 424 Flue Elbow Sealing Gasket 1 212084
13 382 462 Electronic Control 1 407677
14 336 585 Fuse 1 amp 1 641903
15 338 445 Thermostat Knob 1 225251
16 Pressure Switch - 40 1
Pressure Switch - 50 1
Pressure Switch - 60 1
Pressure Switch - 80 1
17 382 445 Fan - 80 1 409569
Fan - 40, 50, 60 1 409583
18 382 455 Overheat Thermostat LM7 P8503 1 404495
19 337 371 Main Burner Gasket 1 212085
20 337 375 Main Burner Injector 3.1 mm - 40 1 410966
337 376 Main Burner Injector 3.5 mm - 50 1 410967
337 377 Main Burner Injector 3.8 mm - 60 1 410968
337 378 Main Burner Injector 4.4 mm - 80 1 410969
21 337 372 Flue Brush (optional extra) 1 212154

Publication No. 5105703 Short List Spare Parts 35

 Publication No. 5105703 - Iss. 01 (08/2001)

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All descriptions and illustrations provided in this leaflet have been care-
fully prepared but we reserve the right to make changes and improve-
ments in our products which may affect the accuracy of the information
contained in this leaflet. All goods are sold subject to our standard
Conditions of Sale which are available on request.

Baxi Potterton
Brownedge Road, Bamber Bridge
Preston, Lancashire
PR5 6SN

www.potterton.co.uk