Potterton 50e Datasheet

LPG 50e, 60e, & 80e, fanned
balanced flue gas fired boilers
THIS APPLIANCE IS FOR USE WITH PROPANE GAS (G31) ONLY
Installation and Servicing Instructions
LEAVE THESE INSTRUCTIONS ADJACENT TO THE APPLIANCE

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2
GAD (90/396/EEC)
IMPORTANT This appliance must be installed and serviced by a competent person as stated in the Gas Safety (Installation
and Use) Regulations 1994.
Profile LPG boilers have been designed to comply with the requirements of BS 5258 Part 1 and BS 6332 Part 1. It is
important that no external control devices (e.g. flue dampers, economisers, etc.) be directly connected to these appliances
unless covered by these installation instructions or otherwise recommended in writing. Any direct connection of a control
device not approved by Potterton could invalidate the normal warranty.
LIST OF CONTENTS - Page 2
General Page No. 2 Site Requirements Page No. 3
Optional Extras Page No. 2 Technical Data Page No. 6
Accessories Page No. 3 Installation Instructions Page No. 11
Installation Data Page No. 3 Commissioning Page No. 18
Boiler Dimensions Page No. 3 Servicing Instructions Page No. 21
Health and Safety Information Back Page
Control Systems, Pipework and
Wiring Guide Supplied in
User’s Instructions Literature Pack
GENERAL - Page 2
Potterton Profile LPG boilers are fully automatically
controlled wall mounted fan powered balanced flue
appliances, using a cast iron heat exchanger and are
available in three outputs. 14.7 kW (50000 Btu/h), 17.6 kW
(60000 Btu/h) and 23.44 kW (80000 Btu/h).
The boilers which are designed to provide domestic hot
water and/or central heating must be used on INDIRECT
hot water systems only. The cast iron heat exchangers are
suitable for use on open vented gravity domestic hot
water/pumped central heating systems or fully pumped
systems which may be sealed or open vented.
All boilers can be supplied with either of the following types
of flue system:
1) Standard horizontal flue system suitable for wall
thickness of 100mm (4 in.) to 510mm (20 in.).
2) 2 metre horizontal flue system which provides a
maximum flue length of 1955mm (77 in.).
3) Vertical flue system which allows the flue to pass
through a flat roof and terminate at a maximum height
of 1980mm (78 in.) measured from the top of the boiler
case.
OPTIONAL EXTRAS - Page 2
The following are kits available as optional extras:-
Internal Fitment Kit, which is suitable for a maximum wall
thickness of 510mm (20 in.) is to be used where access to
the outside wall is impracticable.
Terminal Guard, to be used when the terminal is fitted less
than 2m above a balcony, above ground or above a flat roof
to which people have access.
Full fitting instructions are provided with each kit.
Pump Cover KIts, located on top of the boiler and
designed to conceal the pump, and/or any motorised PART Nos
valves installed above the boiler. (Note: Pump cannot 5Oe 60e 80e
be fitted above the boiler if the vertical flue kit is used. Standard Flue system 225540 225541 225541
2 metre Flue System 225543 225544 225544
Terminal Wall Plate, where necessary can be fitted to Vertical Flue system 213074 213048 213049
the outside wall face to improve the appearance, after Terminal Wall Plate 212306 212280 212280
making good around the terminal. Terminal Guard 205792 205792 205792
Internal Fitment Kit 225183 225184 225184
Pump Cover Kit (6in) 225418 225418 225418
Pump cover Kit (71n - 12in) 225419 225419 225419
Pump Cover Kit (l3in - l8in) 225420 225420 225420
Pump Cover Kit (l9in - 24in) 225421 225421 225421

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ACCESSORIES - Page 3
The following Potterton Myson controls are recommended
for use with your boiler:- Electronic Programmer EP2001,
EP3001, or EP6000
Cylinder Thermostat PTT2 or PTT1 00
Room Thermostat PRT2 or PRT100
Frost Thermostat PRT1 00 FR
Motorised Zone Valve M5V222 or M5V228
Motorised Diverter Valve M5V322
Thermostatic Radiator Valve
Data Sheets describing these products are available on
request.
INSTALLATION DATA - Page 3
The installation of the boiler must be in accordance with the
latest relevant requirements of the Gas Safety (Installation
and Use) Regulations 1984, local building regulations, lEE
Wiring Regulations and the Byelaws of the Local Water
Undertaking.
Detailed recommendations are contained in the following
British Standards and Codes of Practice.
B55482 Part 1, B56798, B55440 Part 1, B55440
Part 2, BS5449 Part 1, B55546, BS4814.
B56891 BUILDING REGULATIONS 1985.
MODEL WATER BYELAWS.
BRITISH GAS PUBLICATION DM2.
GAS SAFETY (INSULATION AND USE) REGULATIONS
1984.
BUILDING STANDARDS (SCOTLAND) REGULATIONS
BOILER DIMENSIONS in mm - Page 3
FIG. 1
SITE REQUIREMENTS - Page 3
These boilers are not suitable for external installation and
should not be fitted directly above a cooking appliance. The
appliance may installed in any room except a cellar or
basement Particular attention is drawn to the requirements
of the current I.E.E. Wiring Regulations and in Scotland, the
electrical provisions of the Building Standards applicable in
Scotland with respect to the installation of the appliance in a
room containing a bath
or shower.
Where a room-sealed appliance is installed in a room
containing a bath or shower, any electrical switch or
appliance control, utilising mains electricity should be so
situated that it cannot be touched by a person using the
bath or shower.

SITE REQUIREMENTS - Page 4
FLOW PIPE FAN RETURN PIPE
FIG. 2 GENERAL ARRANGEMENT

SITE REQUIREMENTS - Page 5
Where the installation of the boiler will be in an unusual
location, special procedures may be necessary and BS
6798 1987 gives detailed guidance on this aspect.
Ensure that the gas supply pipe and meter if fitted are
installed in accordance with B55482 Part 1. Check that they
are large enough for this appliance and any others that may
be run off the same supply. If in doubt seek advice from the
Propane gas supplier.
Boiler Mounting Surface
The boiler must be mounted on a flat wall, which may be of
combustible material and must be sufficiently robust to take
the weight of the boiler. The requirements of the local
authorities and the Building Regulations must be adhered
to.
IMPORTANT NOTICE:
TIMBER FRAMED HOUSES
If the appliance is to be fitted in a timber framed building, it
should be fitted in accordance with British Gas Publication
Operational Procedures for Customer Service’ Part 19. If in‘any
doubt, advice should be sought from the local region of British
Gas.
Clearances Around the Boiler
The following minimum clearances must be maintained after
installation, for correct operation and servicing of the boiler:
610mm (2 ft) at the front of the boiler
5mm (0.2 in) each side of the boiler
50mm (2 in) at the top (measured from the top of the boiler
case), except where the optional extra pump cover is to be
fitted, when 178mm (7 in) should be allowed.
100mm (4 in) at the bottom of the boiler.
Additional clearances to these are required during
installation for lifting the boiler and 127mm (5 in) is required
at the top of the boiler for access to the pipe connections.
Ventilation
If the boiler is to be installed in a confined space such as a
cupboard, the space will need ventilating. Openings must
be provided at the top and bottom of the cupboard each of
which should have a free area as shown in TABLE 1.
Further details for installation of a boiler within a
compartment are given in BS 6798 1987.
TABLE 1 AIR VENT AREAS
PROFILE in2cm2
50e 26 170
60e 32 206
80e 43 277
If the openings draw air from outside the building the free
areas may be halved. Refer to B55440 Part 2 for further
guidance.
Balanced Flue Terminal and Ducting
The fresh air inlet and flue ducts can be run from either the
left, right, rear or top of the boiler to a miniature terminal on
the outside of the building.
The minimum spacings from the terminal to obstructions
and ventilation openings are shown in FIG. 3. For infor-
mation appertaining to horizontal flue lengths reference
should be made to FIG. 4.
If a terminal is fitted less than 2m above a balcony, above
ground or above a flat roof to which people have access
then a suitable terminal guard should be fitted. (P.l.L. No.
205792).
Refer to B55440 Part 1 for further guidance.
INFORMATION RELATING TO VERTICAL FLUING IS
PROVIDED IN THE PACK CONTAINING THE VERTICAL
FLUE SYSTEM.
NOTE
Where a flue terminal is fitted less than 1000mm from a
plastic or painted gutter or 500mm from painted eaves, an
aluminium shield of 1000mm length should befitted to
underside of gutter or eaves.
Any car port or other add-on extension should consist of a
roof or a roof and one other wall. If it consists of a roof and
two other walls - the installation shall be treated as suspect
and further advice sought.
FIG. 3 THE SITING OF BALANCED FLUE TERMINALS
Position Minimum Distance
mm
A
DIRECTLY BELOW AN OPENABLE
WINDOW, AIR VENT, OR ANY OTHER
VENTILATION OEPNING 300
BBELOW GUTTER, DRAIN/SOIL PIPE 25
CBELOW EAVES 25
DBELOW A BALCONY OR CAR PORT ROOF 25
EFROM VERTICAL DRAIN PIPES AND SOIL
PIPES 75
F
FROM INTERNAL OR EXTERNAL
CORNERS 25
G
ABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
H
FROM A SURFACE FACING THE
TERMINAL 600
IFACING TERMINALS 1,200
J. FROM OPENING (DOOR/WINDOW) IN
CARPORT INTO DWELLING 1,200
K. VERTICALLY FROM A TERMINAL ON THE
SAME WALL 1,500
L. HORIZONTALLY FROM A TERMINAL ON
THE SAME WALL 300
M. ADJACENT TO OPENING 150

SITE REQUIREMENTS - Page 6
ALL MODELS REAR OR SIDE FLUEING
FIG. 4 FLUE LENGTHS
ELECTRICITY SUPPLY
A 240 volts ~ 50Hz, single phase electricity supply fused to
3 amperes, must be provided in accordance with the latest
edition of the I.E.E. Wiring Regulations and any other local
regulations that may apply. The current rating of the wiring
to the boiler must exceed 3 amperes and have a cross
sectional area of at least 0.75mm2 in accordance with
BS6500 1975 Table 16.
The supply to the boiler and its associated equipment
should be controlled by an exclusive 3A fused double pole
switch (having at least 3mm contact separation in both
poles) so that complete isolation from the supply can be
achieved to enable servicing work to be carried out in
safety.
TECHNICAL DATA - Page 6
Maximum working head 30.5m (100 ft) Gas supply connection Rc. ½ (½in BSP
Minimum working head on Female)
Fully Pumped systems 305mm (1 ft)
Minimum circulating head Water Content 6.5 litre (1.43 gal)
on Gravity systems 1.2m (4 ft)
Gas supply pressure 37mbar
Maximum Flow temperature 820C
Electricity supply 240v ~ 5OHz fused Appliance Weight-installed 62kg (137 Ibs)
at 3A Appliance Weight-lift 53kg (117 Ibs)
Flow/Return connection 28mm copper
Power consumption 80 watts
(excluding pump)

TECHNICAL DATA - Page 7
BOILER
SIZE INJECTOR SIZE GAS RATE at 95.01- MJ/m3
(2500 Btu/ft3
M3/H (ft 3/h)
INPUT Kw
(Btu/h) OUTPUT
kW(Btu/h) BURNER PRESSURE SUPPLY PRESSURE
50e 2.2mm 0.72 (25.6) 18.75 (64.000) 14.65(50000) 35.6(14.3) 37(14.8)
60e 2.4mm 0.87 (30.8) 22.56 (77.000) 17.6(60000) 35.3(14.2) 37(14.8)
80e 2.8mm 1.17 (41.2) 30.25 (103,000) 23.44(80000) 34.2(13.7) 37(14.8)
CIRCULATION PUMP SELECTION TABLE 2
The resistance - through the heat exchanger when Boiler BOILER RESISTANCE
operating with a water flow rate producing an 11 0Csize Water Flow Rate WITH DISC WITHOUT DISC
temperature rise at maximum boiler output are shown in litres/sec gal/mm kN/m2 in wg kN/m2 in wg
TABLE 2. If other controls, such as three-position valves
are used in the system, the resistance through them, 50e .32 4.17 4.0 16.0 1.25 5.0
quoted in their manufacturer’s literature must be taken 60e .38 5.0 5.7 23.0 1.75 7.0
into account. The pump may be fitted on either the flow 80e .51 6.67 10.5 42.0 3.0 12.0
or return and MUST be wired directly to the boiler
terminal block, see FIG. 24. It must be fitted with two
isolating valves which are positioned as close to the
pump as possible. Closing of any valve must always
leave the open vent unobstructed.
FIG. 5 PRESSURE LOSS ACROSS BOILER

TECHNICAL DATA - Page 8
The System
The boiler must be used on INDIRECT hot water systems only.
It is suitable for use on open vented gravity domestic hot
water/pumped central heating systems or, fully pumped
systems which may be sealed or open vented.
The system should be designed so that the maximum static
head does not exceed 30.5 m (100 ft) and a minimum on fully
pumped systems of 305 mm (1 ft). See FIG. 6.
Gravity domestic hot water circuits should have a minimum
circulating head of 1.2 m (4ft). See FIG. 8.
To ensure optimum boiler performance on both gravity hot
water and fully pumped systems a change-over switch is
incorporated in the boiler control box. The boiler is supplied
with the switch set for sealed or open vented fully pumped
systems.
If the boiler is to be used on a system with gravity hot water the
switch should be set at the GRAVITY position. In addition the
bulb of the overheat thermostat should be repositioned as
shown in FIG. 21.
To prevent reverse circulation in the gravity circuit when the
pump is running an injector disc is provided to form an injector
tee at the return connection on the boiler. See FIG. 20.
On all systems the pump should be wired to the boiler terminal
block. To prevent nuisance operation of the overheat
thermostat, it is important that where electrically operated zone
valves are used the boiler is wired so it does not cycle when
the zone valves are closed. Also, systems fitted with controls
that close both hot water and central heating circuits while the
boiler is still hot, must be fitted with a by-pass circuit to
dissipate the residual heat within the boiler.
Further information on by-pass arrangements is provided in
later notes and illustrations.
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. See FIG. 2.
Combined Gravity Hot Water Pumped Central Heating
Systems. Where a cylinder thermostat and zone valve is used
to control the temperature of the hot water it is recommended
that a by-pass be installed in the gravity circuit. A suggested
method of doing this is shown in FIG. 8 where the bathroom
radiator is connected into the gravity circuit and is fitted with
two Iockshield valves. Mechanically operated thermostatic
domestic hot water temperature control valves which allow the
boiler to operate when the valve is closed or partially closed
MUST NOT BE FITTED.
Fully pumped Systems
With the change-over switch in the control box set at the
FULLY PUMPED position, the pump will be controlled by an
over-run thermostat. This will ensure that the pump will
continue to run after boiler shut down if the water temperature
in the boiler is high, thus preventing nuisance operation of the
overheat thermostat. If a three port diverter valve is used as
shown in FIGS. 6, 7 a by-pass is not necessary since one
circuit is always open.
Where a pair of two port valves are used, a by-pass is
necessary. The total length of the by-pass circuit taken from the
boiler connections should be greater than 4 metres of 22 mm
pipe. It should be fitted with a lockshield valve and be adjusted
to maintain a minimum flow through the boiler of 4.5 litres/mm (1
gal/mm) see FIGS 6, 7.
Systems fitted with controls which allow the boiler to operate
when both the hot water and central heating circuits are closed
i.e. mechanically operated thermostatic control valves, must be
fitted with a by-pass circuit capable of:—
1. Dissipating a minimum of 1 kW (3400 Btu/h)
2. Maintaining a minimum water flow through the boiler of 9
litres/mm (2 gal/mm).
A suggested method of meeting these requirements by using a
bathroom radiator fitted with two lockshield valves is shown in
FIGS. 6, 7.
Additional system information can be found in the Control
Systems, Pipework and Wiring Guide.
SEALED SYSTEMS (FULLY PUMPED)
Installation
The installation must comply with the requirements of BS 6798
1987 and BS 5449 Part 1. The B.G. publication “British Gas
Specification for Domestic Wet Central Heating Systems” should
also be consulted.
Safety Valve
A non adjustable spring-loaded safety valve, preset to operate
at 3 bar (451bf/in2) shall be used. It must comply with BS 6759
Part 1 and include a manual testing device. It shall be positioned
in the flow pipe 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 installed
into a discharge pipe which permits the safe discharge of steam
and hot water such that no hazard to persons or damage to
electrical components is caused.
Pressure Gauge
A pressure gauge incorporating a fill pressure indicator,
covering the range 0-4 bar (60 lbf/in2) shall be fitted to the
system. It should be connected to the system, preferably at the
same point as the expansion vessel. Its location should be
visible from the filling point.
Expansion Vessel
A diaphragm type expansion vessel to 8S4814 Part 1 shall be
fitted close to the inlet side of the pump. The connecting
pipework should not be less than 15 mm (½ in nominal).
Pipework connecting the expansion vessel should not
incorporate valves of any sort. Methods of supporting the vessel
are supplied by the manufacturer. The nitrogen or air charge
pressure of the expansion vessel shall not be less than the
hydrostatic head, (height of the top point of the system above
the expansion vessel). To size the expansion vessel it is first
necessary to calculate the volume of water in the system in
litres. The following volumes may be used as a conservative
guide to calculating the system volume.
Boiler Heat Exchanger: 6.5 litres
Small Bore Pipework: 1 litre per kW of system
output
Micro Bore Pipework: 7 litres
Steel Panel Radiators: 8 litres per kW of system
output
Low Water Capacity Radiators: 2 litres per kW of system
output
Hot water Cylinder: 2 litres

TECHNICAL DATA - Page 9
If the system is extended, the expansion vessel volume may
have to be increased unless previous provision has been
made for the extension. Where a vessel of the calculated
size is not available, the next available larger size should be
used.
The boiler flow temperature is controlled at approximately
820C.
The vessel size can now be determined from the following
table where V=System volume in litres.
Method of Make-Up
Provision shall be made for replacing water loss from the
system either:—
i) from a make-up vessel or tank mounted in a position
higher than the top point of the system, and connected
through a non-return valve to the system on the return
side of hot water cylinder or the return side of all heat
emitters.
or
ii) where access to a make-up vessel would be difficult
Vessel Charge Pressure(bar) 0.5 1.0 by using the mains top up method or a remote
automatic pressurisation and make-up unit as illus-
Initial System Pressure (bar) 1.0 1.0 trated in FIG. 7 METHODS 1 and 2.
Expansion Vessel Volume (litres) V x 0.11 V x 0.087 Mains Connection
There shall be no connection to the mains water supply
or to the water storage tank which supplies domestic water
even through a non-return valve, without the approval of the
local Water Authority.
Cylinder
The hot water cylinder must be an indirect coil type or a
direct cylinder fitted with an immersion calorifier suitable for
operating at a gauge pressure of 0.3 bar (5Ibf/in2) in excess
of safety valve setting. Single feed indirect cylinders are not
suitable for sealed systems.
Filling Point
The system shall be fitted with a filling point at low level
which incorporates a stop valve to BS1 010 and a double
check valve (approved by the National Water Council) to be
fitted in this order from the system mains, Refer to FIG. 7.
Method 1.
FIG. 6 OPEN VENTED FULLY PUMPED SYSTEM
FITTED WITH A COMBINED FEED AND VENT

TECHNICAL DATA - Page 10
FIG 7. FULLY PUMPED SEALED SYSTEM
FIG 8. OPEN VENTED GRAVITY DOMESTIC HOT
WATER PUMPED CENTRAL HEATING SYSTEM

INSTALLATION INSTRUCTIONS - Page 11
It is the law that all gas appliances are installed and
serviced by competent persons as stated in Gas Safety
(Installation and Use) Regulations 1994.
For Health and Safety information see back page.
Electrical installation and servicing should be carried out by
a competent person in accordance with the I.E.E. Wiring
Regulations.
The boiler and its associated equipment will arrive on site in
two cardboard cartons. The contents of each carton is as
follows.
CARTON 1:- Boiler Pack
Boiler
Template
Literature Pack Containing:-
Installation and Servicing Instructions
User’s Instructions
Control Systems Pipework and Wiring Guide
Auxiliary Pack Containing:-
Boiler Mounting Bracket
Gas Service Cock and Accessory Packs
CARTON 2:- Flue System Pack
Standard and 2 metre Horizontal Flue Packs
Air/Flue Duct Assembly (length as ordered)
Flue Elbow Extension
Flue Terminal
Flue Sealing Collar
Rope Sealing Ring
Side Infill Panels-2 off
Vertical Flue Pack (2 cartons)
Air/Flue Duct Assembly Flue Terminal
Terminal Cowl
Vertical Flue Adapter
Accessory Pack
Side Infill Panels-2 off
Flue Installation Instructions
FIG. 9 TEMPLATE FIG. 10 BOILER MOUNTING PLATE
Place template in proposed boiler position ensuring it is
level (the minimum side clearances are automatically
allowed for)
REAR FLUING
Mark holes ‘A’, ‘B’, ‘D’, large flue outlet hole and side of
boiler reference lines throught slots ‘C’.
SIDE FLUING
Mark hole positions ‘A’, ‘D’ and side of boiler reference lines
through slots ‘C’.
Mark large flue outlet hole and holes ‘B’ using the thick lines
on the template for minimum clearance at the rear of the
boiler and the thin dotted lines for maximum clearance. See
NOTE on FIG. 1.
Remove template and carefully cut flue outlet hole through
wall. If necessary make good around hole to enable holes
‘B’ to be drilled. (If internal flue fitment kit is being used refer
to instructions supplied with kit).
Drill holes ‘A’ using a 7 mm drill
Drill holes ‘B’ and ‘D’ using a 5 mm drill
Using wall plugs, screws and washers (accessory pack A)
attach boiler mounting plate to wall. Ensure that it is level
and the correct way up, i.e. to provide the clearance at the
rear of the boiler allowed for when marking out using the
template. See also NOTE on FIG. 1.
Insert wall plugs into holes ‘B’ (accessory pack B) and hole
‘D’ (accessory pack D).
Insert flue sealing collar into wall and secure with screws
provided, (accessory pack B). Make good the internal wall
surface around flue sealing collar.

INSTALLATION INSTRUCTIONS - Page 12
FIG. 11 a SIDE FLUE FIG. 11 b REAR 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 20mm. Ensure that both
ducts are cut squarely.
1. Measure wall thickness (dimension ‘Y’).
2. Take air/flue duct assembly and measuring from the
flanged end, mark and cut the outer air duct and inner
flue duct to dimension ‘Y’, plus 45 mm. Ensure that both
ducts are cut squarely.
NOTE
Cutting length remains the same for minimum or
maximum clearance at the rear of the boiler
FIG. 12 AIR/FLUE DUCT ASSEMBLY
NOTE: During assembly the seam in the air duct should be
so arranged that when installed, the seam in the duct will be
uppermost.
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.
3. Engage four screws from accessory pack “C” into the
pre-drilled holes in the terminal and screw fully home.
These screws which are self drilling will pierce the air
duct and secure the terminal to air duct. On model 50e
it is necessary to drill four pilot holes in the air duct.

INSTALLATION INSTRUCTIONS - Page 13
FIG. 13 SECTIONAL VIEW OF AIR/FLUE DUCT ASSY
THROUGH WALL
4. Protect duct where it is likely to come into contact with
mortar by using adhesive tape provided (accessory
pack E).
5. Insert the assembly into the wall sliding the rope sealing
ring along the air duct into the flue sealing collar. Bend
the six tabs on flue sealing collar inwards to retain the
rope sealing ring. Ensure air duct flange studs do not
obstruct lifting of boiler onto mounting bracket.
FIG. 14 PREPARING BOILER
The controls cover should have been removed when
unpacking the boiler, if not remove controls cover by
opening the door covering the securing screw on the
underside of the controls cover, see FIG. 14. Undo securing
screw, pull controls cover forward 10mm, 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
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.
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.
NOTE:
If side fluing, loosen the two brass securing nuts
beneath the flue elbow outlet and remove the other two.
Tilt the flange and withdraw the elbow.
The boiler is supplied with the left hand flue outlet sealing
plate removed. If another flue outlet direction is required,
remove the appropriate flue outlet sealing plate and transfer
it to the left hand position.

INSTALLATION INSTRUCTIONS - Page 14
LIFTING THE BOILER
Lift the boiler onto its mounting bracket.
FIG. 15
FIG. 16 TRANSPORTATION FOOT
Locate the studs on the air duct flange through the boiler
casing and secure using four wing nuts (accessory pack
F).
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. See FIGS. 16 & 17.
FIG. 17 SECURING BOILER
FIG. 18 FLUE ELBOW EXTENSION
Rotate the left hand adjustment screw to align one of the
holes in the base plate with 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.
When side fluing, slide the elbow extension onto the elbow
and ensure that it is pushed on fully. Engage the screw from
accessory pack ‘C’ into the pre-drilled hole in the elbow
extension and screw fully home. The screw which is self
drilling will pierce the elbow and secure the extension to the
elbow.
When rear fluing, the elbow extension should be discarded.

INSTALLATION INSTRUCTIONS - Page 15
FIG. 19 LOCATION OF PRESSURE
SENSING TUBES
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. Reconnect flexible tubes to elbow.
ENSURE THEY ARE NOT KINKED. NOTE: Red tube
connects the front aluminium tube in upper chamber to the
lower connection on elbow, each being identified with a red
ring.
FIG 20. PIPE CONNECTIONS
Connect system pipework to the boiler, compression fittings
should be used. 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 28mm tees fitted directly to the flow and return
pipes on the boiler.
The gravity circuit should be installed in 28mm copper pipe.
The larger injector disc provided in accessory pack H must
be positioned in the pumped return branch of the tee and
the pipes connected to the tees as illustrated in Figs. 20 and
20B. The small injector disc should be discarded.
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.
FIG. 20B WARNING: UNDER NO CIRCUMSTANCES SHOULD A ‘REDUCING SET’ BE FITTED

INSTALLATION INSTRUCTIONS - Page 16
FIG. 21 OVERHEAT THERMOSTAT BULB
POSITION
ELECTRICAL
The boiler and all external control circuit wiring must be
supplied from the same single isolating switch or plug and
socket, and should be fused at 3A. Care must be taken to
ensure that all wiring to the boiler is kept clear of sharp
edges and hot surfaces.
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. 2.
If the boiler is to be used on a GRAVITY DHW system the
bulb of the overheat thermostat must be repositioned as
shown in FIG. 21. To do this loosen the plastic retaining
screw and withdraw the thermostat bulb from its pocket.
Position the bulb as illustrated and secure it by finger
tightening the plastic screw. Do not over-tighten.
FIG. 22 PRINCIPLE OF WIRING
FIG. 23 ACCESS TO THE BOILER ELECTRICAL
TERMINAL BLOCK
The boiler terminal block which is situated in the control box
is not designed to accept wiring from all the on site controls
and therefore the installer will usually need to 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 in FIG. 22.
Further information on wiring of system controls can be
found in the Control System, Pipework and Wiring Guide.
Remove control box securing screw and lower the control
box to gain access to the boiler terminal block.

INSTALLATION INSTRUCTIONS - Page 17
FIG. 24 ROUTING OF ELECTRICAL WIRING
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.
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.
Permanent live to terminal marked MAINS ‘L’.
Neutral to terminal marked MAINS ‘N’.
Earth to terminal marked ‘ ’ adjacent to cable clamp.
See NOTE.
Switched live from external controls to terminal marked
MAINS ‘SwL’.
If there are no external controls filled connect the SwL
terminal to permanent live in the junction box.
Gravity Domestic Hot Water/Pumped Central Heating
Systems.
Switched live from external gravity domestic hot water
control circuit to terminal marked 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 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.
FITTING SIDE INFILL PANELS
If required, the gap between the casing sides and rear wall
can be closed off using the inf ill panels supplied.
Minimum or maximum rear boiler clearance is catered for by
turning the infill panel. Attach each infill panel to the rear of
the boiler using two pieces of magnetic strip and an edge
clip (accessory pack G) positioned as illustrated.

COMMISSIONING - Page 18
Open Vented Systems
Remove the pump and flush out the system thoroughly with
cold water. Refit the pump. Fill and vent the system.
Examine for leaks.
Sealed Systems
NOTE:
The system can be filled using a sealed system filler pump
with a break tank or by any other method approved by the
Local Water Authority. Refer to ‘THE SYSTEM’ section
Page 8 in these instructions, also BS 6798.
Remove pump and flush out the system thoroughly with
cold water. Refit the pump. Fill and vent the system until the
pressure gauge registers 1.5 bar (21.5 lbf/in2). Examine for
leaks. Raise the pressure until the safety valve lifts. This
should occur within 1 0.3 bar of the preset lift pressure of 3
bar. Release water to attain the correct cold fill pressure.
All Systems
Refit the fan assembly and reconnect the fan supply leads,
(polarity of the fan leads is not important).
The whole of the gas installation including the meter (if
fitted) should be inspected and tested for soundness and
purged in accordance with the recommendations of B55482
Part 1.
Test pilot unions for gas soundness as follows:—
Turn boiler thermostat to the ‘0’ position.
Unplug the gas control valve supply lead from the control
box and plug it into the test socket adjacent to the boiler
thermostat knob, see FIG. 24.
Turn on gas at the gas service cock.
Ensure that the time control if fitted is in an ON condition,
and that the room and/or cylinder thermostats where fitted
are set to high temperatures.
Switch on the external electricity supply to the boiler.
Gas will flow to the pilot only. It will not be ignited as the
ignition system is de-energised.
Using a leak detection fluid, check pilot unions for gas
soundness.
Turn off the external electicity supply and gas service cock.
Remove gas control valve plug from the test socket and refit
the plug into the socket on the left hand side of the control
box see FIG. 24.
Refit the combustion chamber front panel.
Fit the case door into position by lifting it onto the top hinge
brackets and secure it with the lower two fixing screws.
ENSURE THAT A GOOD SEAL IS OBTAINED
Remove the temporary label from the front of the casing,
having checked compliance with the information it contains.
First Lighting
WARNING: Before lighting the boiler, ensure that the CASE
DOOR HAS BEEN CORRECTLY FITTED and that the
sealing strip fitted to the case door is forming a tight seal
with the main boiler casing. Before proceeding to light the
boiler, check that the external electricity supply to the boiler
is switched off and that the boiler thermostat is in the ‘0’
position.
Turn on the gas service cock.
Ensure that the pump and radiator isolating valves are
open.
Ensure that the time control, if fitted is in an on condition,
and that the room and/or cylinder thermostats, where fitted
are set to high temperatures.
Switch on the external electricity supply to the boiler.
In the event of an electrical fault after installation of the
appliance, preliminary electrical system checks must be
carried out as described in the BG multimeter instruction
book. The checks to be carried out are:-
A. Earth Continuity
B. Short Circuit
C. Polarity
D. Resistance to Earth
Refer to Fault Finding Chart FIG. 31
Turn the boiler thermostat on and to a high setting and after
a period of time the main burner will light, this can be
observed through the sight glass in the front cover of the
boiler. The time period can vary upwards of 45 seconds,
depending on the amount of air in the pipework.
Test for gas soundness around the boiler components using
leak detection fluid.
Turn the boiler thermostat to ‘0’.
NOTE:
There could be a delay in lighting if the control knob is
switched on and off and then on again rapidly.
SETTING AND CHECKING OF CONTROLS
With the controls cover removed.
Fit a pressure gauge to the pressure test nipple in burner
supply pipe. See FIG. 2.
Turn on the boiler thermostat and ensure that the main
burner is alight.
Ten minutes after lighting check that the burner pressure is
in accordance with the values stated under TECHNICAL
DATA. On the first main burner ignition of a newly installed
boiler, supplied from a new bulk storage
installation, some noise may be emitted due to air in the
pipeline. This noise may persist on subsequent ignitions for
a day or two according to usage, until any air remaining in
the supply system has been purged.

COMMISSIONING - Page 19
FIG. 26
Shut down the boiler remove the pressure gauge and refit
the screw in the test nipple ensuring that a tight seal is
made.
Refit the controls cover.
Relight the boiler and heat the system to maximum. Check
for water leaks, turn the boiler off, drain the system whilst
hot.
Refill the system and on sealed systems adjust to the
correct cold fill pressure. Set the pressure gauge pointer to
the system design pressure.
If a by-pass circuit is fitted the by-pass valve should be
adjusted with the boiler operating under minimum load
conditions to maintain sufficient water flow through the
boiler to ensure that the overheat thermostat does not
operate under normal operating conditions.
Pilot Burner
The pilot is pre-set and no adjustment is required. The pilot
flame envelope should cover the electrode tip, see FIG. 30.
If the pilot flame is not as illustrated, remove and clean the
pilot as described in the Servicing Instructions Section 3,
PILOT BURNER, Page 22.
Boiler Thermostat
At its minimum and maximum settings, the thermostat
should control the water flow temperature at approximately
550C—820C (1 300F— 1 800F).
The thermostat has been calibrated by the makers and no
attempt should be made to re-calibrate it on site. Turn the
thermostat to the ‘0’ position and check that the main burner
shuts down.
Gravity Hot Water/Pump Over-Run Thermostat
The function of this thermostat is determined by the position
in which the GRAVITY/FULLY PUMPED SYSTEM selection
switch is set. The thermostat is pre-set and no adjustment is
possible.
On the FULLY PUMPED switch position it will operate as a
pump over-run thermostat and will keep the pump running
after the boiler has shut down, as long as the water
temperature within the boiler is above approximately 800C.
On the GRAVITY switch position it will operate in series with
the boiler thermostat when only the gravity domestic hot
water circuit is in operation.
It will over-ride the boiler thermostat when the water
temperature within the boiler is above 800C.
Overheat Thermostat
The overheat thermostat is pre-set and no adjustment is
possible. It will require manually resetting if an overheat
condition occurs. Access to the reset button is through a hole
in the underside of the controls cover, see
FIG. 2.
Other Boiler Controls
All boiler mounted controls are designed so that if any fault
should occur they will fail safe. No further setting or checking
is necessary.
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.

COMMISSIONING - Page 20
HONEYWELL
FIG. 28 BOILER WIRING DIAGRAM