Potterton Isis HE Instruction manual

MAY 2004

INDEX
SECTION 1 Page
Fig 1 - General Data & Dimensions 1
Table 1 - Boiler Dimensions 1
Table 2 - Combustion Chamber Data 1
Table 3 - Technical Data 2
- Technical Data 3
Fig 2 - Base Details 4
- Clearances/ Burner Information 4
Fig 3 - Boiler Water Connections (6-7 Sect) 5
Fig.4 - Boiler Water Connections (8-15 Sect) 5
SECTION 2
- General Information 6
- Installation 7
- Boiler Siting and Base 7
SECTION 3
- Ventilation 8
- Flue 8
- Flue Size Considerations 8
- Water Circulation Systems 8
- Boiler Protection 9
- System Water Quality 9
SECTION 4
- Boiler Erection 10
- Risk Assessment 10
- C.O.S.H.H. 11
- Erection/Assembly Check List 11
- Waterway Sealing 12
- Erection Procedure 12
Table 4 - Section Build Data/Boiler Sealant
Details 13
Fig.5 - Waterway Sealing Details 13
- Checking For Leaks 14
- Boiler Dismantling 15
- Fitting the Casing 15
Fig.7 - Boiler Insulation 15
Fig.8 - Fitting Locknuts to Studs 15
Fig.9 - Front Panel Fixing 15
Fig.10 - Door Fixing 16
Fig.11 - Door Micro Switch 16
Fig.12 - Firing Door Casing & Insulation 16
Fig.13 - Control Panel 17
Fig.14 - Rear Casing 17
Fig.15 - Boiler Side Rails 17
Fig.16 - Boiler Side Panel Fixing 17
Fig.17 - Side/Front Panel Fixing 18
- Fitting the Inserts 18
- Insert Removal 18
- Boiler Tool Storage 18
- Cafco Blaze Preparation 19
Table 5 - Insert Dimensions 19
Fig.18 - Insert Position 19
SECTION 5 Page
- Boiler Maintenance 20
- Cleaning of Flue Surfaces 20
- Class ‘D’ Fuel Oil 20
- Classes ‘E’ and ‘F’ Fuel Oils and 20
Sludge Gas
- Boiler Ancillaries 20
- Boiler Controls 21
- Commissioning 21
- Additional Checks 22
- Combustion Analysis (NG) 22
- Burner Fan Rotation 22
- Fault Finding 22
- Overheat Operation 22
- Burner Lockout 22
SECTION 6
Fig.20 - Control Panel Wiring 23
Fig.21 - Pump Overrun Using Changeover 24
Pipe Thermostat
Fig.22 - Volt Free Connections 24
SECTION 7
- Casing Pack Details/Part Nos. 25-
29

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 1
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 1
ISIS HE
Fig.1 - General Data & Dimensions (NOT TO SCALE - All measurements in millimetres)
Table 1 – Boiler Dimensions
No of Sections 6 7 8 9 10 11 12 13 14 15
“L” mm 1255 1435 1615 1795 1975 2155 2335 2515 2695 2875
“D” (Diameter) mm 250 350
“B” (Diameter) mm 970 1150 1330 1550 1690 1870 2050 2230 2410 2590
NOTE: Each boiler is supplied with 2 x 3”-4” extension turrets, 2 x 3” flanges, 1 x blank flange, 1 x 1” flange for
drain cock and 1 x flange for thermostat connections.
Table 2 - Combustion Chamber Data
No of Sections 6 7 8 9 10 11 12 13 14 15
Mean Diameter mm 635
Cross Sectional Area m² 0.343
Length mm 920 1100 1280 1460 1640 1820 2000 2180 2360 2540
Volume m30.291 0.349 0.407 0.465 0.522 0.581 0.639 0.697 0.754 0.811
Surface Area m22.15 2.51 2.86 3.22 3.58 3.94 4.3 4.65 5.01 5.38
Resistance mm 38 55 73 57 71 67 73 57 100
Flue Gas Temperature
(Gross) °C 180
Efficiency (Net) %
(Gross) %
90
82.2
Percentage CO2Oil %
Gas %
12
9
Heat Release kW/m² 249.3 250.6 244.1 253.7 259.5 259.9 262.3 262.2 254.3 265.6
D
1070 205 195
100
P
1405
690
373
200
830
210
70
1" BSP
Drain
Connection
Control
Panel
L
Special flue adapter
box available for 6-9
section boiler only
REAR SIDE
For P dimension refer to burner data sheet
200
690
1050
B
Note: Base must not
protrude from rear of boiler.

SECTION 1 POTTERTON COMMERCIAL PRODUCTS DIVISION
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 2
ISIS HE
Table 3 – Technical Data
Number of Sections 6 7 8 9 10 11 12 13 14 15
CE Number BG/EC87/97/127
Output kW 440 516 586 670 762 840 925 1000 1070 1172
Input (Gross) GAS kW
OIL kW
536
514
629
603
714
685
817
783
929
891
1024
982
1128
1082
1219
1169
1305
1251
1429
1370
Input (Net) GAS kW
OIL kW
483
482
567
566
643
642
736
734
837
836
922
921
1016
1015
1098
1096
1175
1173
1287
1285
1Fuel GAS m3/hr
Consumption OIL lit/hr
50
47.6
58.7
55.9
66.7
63.5
76.2
72.6
86.6
82.6
95.5
91
105.2
100.3
113.7
108.3
118.8
115.9
133.3
127
Maximum Design
Pressure Bar 6 BAR ALL MODELS
2Minimum Operating
Pressure Bar 0.5 BAR ALL MODELS
3 Nominal Flue
Connection Size 250mm DIAMETER 350mm DIAMETER
4Flue Gas Volume m3/hr 656 770 874 999 1135 1252 1379 1491 1597 1748
Flue Draught Requirements 0 – 4 mm ALL MODELS
5High Level Natural
Ventilation to BS 6644 cm21342 1550 1742 1973 2225 2439 2673 2878 3070 3350
5Low Ventilation Natural
Ventilation to BS 6644 cm2 2684 3101 3485 3946 4451 4851 5346 5757 6141 6700
6Mechanical Inlet to
BS 6644 m3/sec 0.482 0.566 0.644 0.735 0.836 0.922 1.02 1.097 1.175 1.286
7Water Connection Size
(See Fig.3 & 4) BSP 3'' 4''
8Water Flow
at 11°C ∆t lit/sec 9.5 11 12.6 14.5 16.5 18.2 20.1 21.7 23.2 25.4
8Minimum Water Flow
at 11oC ∆ t lit/sec 5.2 6.1 6.9 8.0 9.1 10 11 11.9 12.8 14
8Hydraulic Resistance
at 11°C ∆t kPa 2.8 4 5 6.5 8.2 11 13 14.5 15 21
9Cold Feet Size to BS
6644 Minimum Bore mm 38 50
9Open Vent Size to BS
6644 Minimum Bore mm 50 65 80
Safety Valve Size to BS
6644 Nominal Size mm 32 40 50 65 80
2Maximum
Flow Temperature °C 90°C ALL MODELS
10 Minimum Return
Temperature °C 55°C ALL MODELS
11 Dry Weight kg 1460 1655 1850 2035 2230 2425 2620 2870 3065 3265
Water Content kg 285 330 375 420 465 510 555 600 645 690
Power Requirements 415V ALL MODELS
For metric to imperial conversions refer to chart inside back cover

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 1
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 3
ISIS HE
1. FUEL CONSUMPTION
Gas fuel consumption is based on natural gas with a gross calorific value of 38.6 Mj/m3. The gas rate
should be corrected for the meter supply pressure particularly on high pressure supplies to prevent
overfiring.
Oil fuel consumption is based on Class D (35 second) gas oil with a gross calorific value of
45.5 Mj/kg. Kerosene has a gross calorific value of 46.5 Mj/lit.
2. MINIMUM OPERATING PRESSURE
This is the minimum operating pressure of the boiler with pumps operating (NOT static pressure). The
requirements of the Health & Safety Executive guidance note PM5 regarding maximum operating
temperatures should be observed.
3. BOILER FLUE CONNECTION
This is the nominal flue size of the flue connection spigot, for dimensional details of the flue connection
spigot see Fig.1. Actual flue size required to achieve correct draught and operation under all running
conditions may need to be increased.
4. FLUE GAS VOLUME
Flue gas volumes are given at STP (standard temperature and pressure 15°C and 1013.25 mbar). Typical
flue gas temperatures are 220°C at CO2 levels of 9% and 12% respectively on gas and oil
5. NATURAL VENTILATION
The sizes indicated are free grille areas and are based on a single boiler installation.
6. MECHANICAL VENTILATION
The volume given is for a single boiler installation.
7. WATER CONNECTION SIZES
The boiler connections are flanged with 3'' BSP screwed counter flanges provided. For further details on
water connections see Fig.3 and Fig.4 3'' – 4'' extension turrets are provided with 4” weldable flanges.
8. WATER FLOW RATES
Water flow rates are given for boiler flow and return temperature differences of 11°C and 20°C.
9. COLD FEED/OPEN VENT/SAFETY VALVE SIZES
Sizes indicated are minimum sizes for single boiler installations.
10. MINIMUM RETURN TEMPERATURE
If system return temperatures below 55°C are required then contact the Potterton Commercial Technical
Department.
11. WEIGHT
The dry weight is exclusive of the burner and gas train, see burner data table for relevant burner weights.
Each section measures approximately 1.4m x 1m x 0.18m and weights 196kg (front), 185kg (intermediate)
and 200kg (rear).
NOTE: ANY PERSON OR PERSONS MOVING OR LIFTING SHOULD BE TRAINED IN MANUAL
HANDLING TECHNIQUES AND IF NECESSARY USE SUITABLE LIFTING EQUIPMENT TO REDUCE
THE RISK OF INJURY TO THEMSELVES OR OTHER PEOPLE.
12. Some burners may require higher than 17.0 mbar inlet pressure, please see relevant burner card for
details, or contact the Commercial Technical Office.

SECTION 1 POTTERTON COMMERCIAL PRODUCTS DIVISION
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 4
ISIS HE
Fig.2 – Isis Base Details
Model Length (B)
Of Plinth
6970
71150
81330
91510
10 1690
11 1870
12 2050
13 2230
14 2410
15 2590
CLEARANCES
The minimum boiler room clearances for access, erection and maintenance are as follows:-
REAR - 500mm (19.7 in) or sufficient to make flue and water connections.
SIDES - 200mm (7.9 in) + burner projection on one side, 500mm on the other.
FRONT - The length of the boiler to allow for cleaning, 1100mm minimum.
BURNER INFORMATION
For general dimensions and specifications see Potterton Isis burner data sheets. (NB: There is a separate data
sheet for each burner type, eg. NuWay, Riello, EOGB.)
The burner should be fitted in accordance with the instructions in Section 4.
The burner unit should be commissioned in accordance with the manufacturers instructions and Potterton burner
card supplied with the burner to obtain the combustion figures detailed. Burner commissioning requires specialist
knowledge and equipment. We therefore strongly recommend that the services of the Potterton Service
Department should be used.
Feet details shown are from a 6
section boiler. For larger models
additional intermediate section feet
are added on 180mm spacing
160
100
40
60
160
180
180
180
160
300
Rear of Plinth
1050
B
Front of Plinth
NOTE: Boiler base MUST NOT
Protrude from rear of boiler

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 1
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 5
ISIS HE
Fig.3 – Boiler Water Connections (6 & 7 Section)
Fig.4 – Boiler Water Connections (8 – 15 Section)
A/B = Interconnected Flow
C = Return
= 3'' to 4'' Extension Turret
A = Flow B = Return A/B = Interconnected Flow
C = Return
A = 3" B = 3"
C = 3"
A
= 3" B = 3"
A/B = 2.5"
A
= 3" B = 4"
A
/B = 3"
Flow = 4"
C = 4"
A
= 3" B = 4"
A
/B = 4"
Flow = 4"
C = 4"
Flow Return
Return
Flow
Return Return

SECTION 2 POTTERTON COMMERCIAL PRODUCTS DIVISION
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 6
ISIS HE
GENERAL
This Boiler is NOT SUITABLE for installation in a
normally occupied area. (i.e. Kitchen).
A LIFETIME GAURANTEE is available on this boiler
please refer to our standard terms and conditions for
details.
The Potterton Isis HE cast iron sectional boiler
available in outputs from 440 kW (6 section model) to
1172 kw (15 section model). Specially designed and
prewired control panels allow full boiler control. Table 3
gives kW output and technical data for each model.
The boiler has a match tested package burners,
available for Natural Gas, LPG, 35 Second & 28
second Oil. Dual Fuel options are also available. The
package burner is supported on the front waterway
section to which it is attached by hinges on one side
and locking nuts on the other. Hinge points are
interchangeable allowing for left or right hand door
opening by turning the door through 180° at the
erection stage.
The Isis HE is suitable for use on fully pumped open
vented or sealed systems with a maximum design
pressure of 6-bar (87 p.s.i.) and up to a maximum
operating temperature of 90°C.
The Isis HE boiler is an overpressure type with three
pass, reverse flame design. The first two passes in the
combustion chamber, the third in the convection tubes
where the turbulence to achieve high heat transfer is
generated by the extended surface area and inserts
achieving operating efficiencies of up to 85.5% gross
CV (91% nett CV).
The Isis HE is constructed with BS1452 Grade220 cast
iron heat exchanger, constructed in accordance with
EN303.1 The boiler package meets Gas and Oil
requirements of M&E3 and burners EN767.
The waterway sections are joined with ‘O’ rings and
secured with tie rods with the final sealing of the
combustion chamber being made during assembly with
boiler cement and silicone rubber.
The boilers are supplied unassembled and the largest
individual section is approximately 1.4m x 1m x 0.18m
and weighs approximately 198 kg.
A 70mm thick insulating blanket encloses the
assembled waterway sections and the complete unit is
enclosed with pre-coated steel panels finished in red.
Standard Supply
•Unassembled cast iron sections (number
dependent on boiler output).
•Flue Spigot, insert tubes, combustion chamber
door, burner adaptor plate, flanges, extension
turrets.
•Boiler wrap around insulation
•Insulated casing
•Cleaning tools
•Control Panel
Controls
The Isis HE range are supplied as standard with an
integral control panel which is fitted with boiler on/off
control thermostat, high/low thermostat limit
thermostat, boiler thermometer, water pressure gauge
and overheat indicator light.
A 240V single-phase supply is taken to the control
panel. A 415V three-phase supply should be taken to
the burner motor connections.
Optional Extras
•Volt free contacts
•Fully closing dampers
Shipping – Packaging
The boiler package is delivered unassembled on
two/three pallets depending on size with the burner
separately either in a carton or pallet.
It is recommended that the manufacturer’s trained
engineers should carry out erection and
commissioning, as will make valid the LIFETIME
GUARANTEE. See back page of this manual for
service office addresses.

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 2
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 7
ISIS HE
INSTALLATION
Before starting work a risk assessment should be
carried out in the boiler and its access to determine
and ensure a safe installation and working
environment.
Any person installing or working on the boiler must be
qualified & competent, and in the case of gas fired
boilers attention is drawn to the mandatory
requirement of C.O.R.G.I Registration and qualified to
A.C.O.P’s element 16. Also they must be electrically
competent and adhere to the IEE regulations.
Manual Handling – Any person or persons moving or
lifting the boiler or any part of it, should be trained in
manual handling techniques and if necessary use
suitable lifting equipment to reduce the risk of injury to
themselves or other people.
The installation should comply with relevant British
Standard Specifications, Codes of Practice and current
Building Regulations, together with any special
regional requirements of the Local Authorities, Gas
Undertaking and Insurance Company. All electrical
wiring must comply with the IEE Regulations for the
Electrical Equipment of Buildings.
The installation of the boiler must be in accordance
with the relevant requirements of: -
•Health & Safety at Work Act 1974.
•Building Regulations 1991
•Electricity at Work Regulations 1989
•Management of H&S at Work Regulations 1992
•Manual Handling Regulations 1992
•Model Water By-laws 1986
•BS 7671: 1992 – Requirements for Electrical
Installations, IEE Wiring Regulations 16th Edition
•BS 6644: 1991 – Installation of Gas Fired Hot
Water Boilers for Inputs between 60kW and 2MW
•BS 7074: 1989 – Part 2 – Application Selection &
Installation of Expansion Vessels & Ancillary
Equipment for Sealed Water Systems
•BS 6880: 1988 – Codes of Practice for Low
Temperature Hot Water Systems
•BS 779: 1989 – Cast Iron Boiler for Central
Heating & Indirect Hot water Supply (Rated Output
44kW and above)
•CP342.2 – Centralised Hot Water Supply
•Gas Safety (Installation & Use) Regulations 1994
•IM/11 Flues for Commercial and Industrial gas
Fired Boilers and Air Heaters
•IGE/UP/1 – Soundness Testing & Purging
Procedure for Non-domestic Installations
•IGE/UP/2 – Gas Installation Pipework, Boosters &
Compressors for Industrial & Commercial
Premises.
•BS EN 303.1 & 303
In the event of a gas booster being necessary refer to
IM/16 ‘Guidance Notes on the Installation of Gas
Pipework, Boosters and Compressors in Customers
Premises’ and the Gas Act 1972, Schedule 4,
Paragraph 18.
Manufacturers notes must not be taken in any way as
overriding statutory obligations.
In addition for oil fired appliances refer to the
following:-
BS 799 Oil Burning Equipment.
BOILER SITING AND BASE
The boiler should be sited in accordance with BS 6644:
1991 with respect to protecting the boiler from
damage, air for combustion and ventilation discharge
of products of combustion, clearances for service and
access, temperatures, noise levels, the disposal of
boiler water and the effects of flooding of the boiler
house or seepage from a roof top boiler house. See
section 1 for required boiler clearances for service and
access.
IMPORTANT: Boiler base must not protrude from rear
of boiler otherwise difficulty will occur in fitting 3"- 4"
extension turrets on rear return connections.
A level non-combustible floor capable of supporting the
weight of the boiler filled with water, see technical data,
together with any additional weight bearing down on
the base from connections, burner, etc, must be
provided. This will typically be a 50mm concrete plinth
with an area equal to that of the plan of the boiler.
Consideration should be given to fitting steel strips
beneath the boiler feet for boiler base protection, see
Fig.2 for base details.
The boiler has a water cooled base and no special
insulation is required. When preparing a site,
reference should be made to Local Authorities and
Building Regulations 1992.
Before any work takes place Risk Assessments should
be carried out, to determine what possible risks are
associated with the work which is taking place.
L.P.G boilers should not be installed in
basements/below ground or in a well.
It is not recommended to install commercial boilers in
kitchen or living areas.
For further advice on installations, refer to
Potterton Technical Bulletins 1 –4.

SECTION 3 POTTERTON COMMERCIAL PRODUCTS DIVISION
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 8
ISIS HE
VENTILATION
Safe, efficient and trouble free operation of
conventionally flued boilers is vitally dependent on
the provision of an adequate supply of fresh air to the
room in which the appliance is installed. Account
must also be taken of any other fuel burning
appliance existing or to be fitted when designing the
ventilation and combustion air systems.
IMPORTANT: The use of an extractor fan in the
same room as the boiler (or in an adjacent room
in communication) can, in certain conditions,
adversely affect the safe operation of the boiler
and therefore must be avoided.
Further guidance on ventilation for gas appliances is
provided by BS 6644: 1991. For oil see relevant
Standard.
FLUE
To ensure safe and satisfactory operation the
chimney system, which may be individual or common
in the case of modular boiler installations, shall be
capable of the complete evacuation of combustion
products at all times. The effective height of the
chimney terminal(s) above the boiler(s) flue outlet(s)
shall ensure sufficient buoyancy to overcome the
resistance of the bends, tees and runs of the flue
pipe involved and shall terminate in a down draught
free zone. The number of bends used should be
kept to a minimum and runs of flue pipe less than 45°
to the horizontal should be avoided in order to
comply with the recommendations made in BS 6644:
1991 and British Gas publication IM/11 "Flues for
Commercial and Industrial Gas Fired Boilers and Air
Heaters". The third edition of the 1956 Clean Air Act
Memorandum and the Building Regulations should
be strictly observed and approval obtained where
applicable, combustion chamber details are given in
section 1.
The flue system must be designed to work
specifically to remove the products of combustion.
IMPORTANT: 90° square bends must not be used
on the flue system, including the boiler flue
spigot, a straight length followed by an "easy
sweep" or lobster back bend should be used.
FLUE SIZE CONSIDERATIONS
Nominal flue connection sizes are given in Table 3,
these sizes refer to the boiler flue connection spigot.
The actual size of the flue system will depend on
individual site applications. Below are general
considerations on sizing flue systems.
Horizontal Flue Runs
Horizontal flue runs are not recommended
particularly over 3m in length, where these are
unavoidable advice should be sought from a flue
system specialist.
Common Flue Systems
Where multiple boilers are installed on a common
flue system then the flue system should be designed
to ensure the correct operation of the flue on varying
load conditions. In particular that the appliance flue
draught is within the operating parameter under full
load and partial load conditions. For safe and
reliable operation of the boiler plant it is
recommended that the variance in flue draught
available at each appliance under full and part load
operation is designed to a minimum.
(It is essential that the services of a specialist
flue system manufacturer are sought for the
design of common flue systems).
For further information regarding ventilation and
flueing see Potterton Technical Bulletin No.4, current
issue or see relevant British Standard publication
BS6644: 1991.
THE ABOVE RECOMMENDATIONS ARE FOR
GENERAL GUIDANCE ONLY. POTTERTON
COMMERCIAL DIVISION CANNOT ACCEPT
RESPONSIBILITY FOR FLUE SYSTEM DESIGNS
BASED ON THE ABOVE RECOMMENDATIONS.
WATER CIRCULATION SYSTEMS
The water circulation system should be indirect and
installed in accordance with the relevant parts of
British Standards Codes of Practice CP342.2 and BS
6644: 1991.
The maximum and minimum design temperature
differential across the boiler should be 20°C and
10°C and the boiler should be prevented from
operating with flow rates giving a temperature
difference across the boiler greater than 25°C based
on the full boiler output.
It is essential that all pipework connections to the
boiler are self supporting, correctly aligned and
allow for free expansion of both boiler and
pipework.
Care should be taken in the pipework design to
prevent strain on the connections. Excessive
strain can lead to premature failure of the boiler,
which is obviously outside the terms of our
warranty.
The use of expansion bellows to take up both
axial and lateral movement is recommended.

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 3
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 9
ISIS HE

SECTION 3 POTTERTON COMMERCIAL PRODUCTS DIVISION
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 10
ISIS HE
Boilers operating under constant flow conditions can
be more accurately controlled and are not subject to
excessive temperature stresses.
The boilers MUST NOT be fired under any
circumstances with less than the minimum water
flow.
On systems with variable flow rates due to flow
reducing devices, ie. TRVs, zone valves, etc, or
where the minimum heat demand, ie. summer
domestic hot water load, does not achieve the
minimum boiler flow rate then consideration shall be
given to incorporating a primary loop system.
It is recommended that the system is designed to
give a constant boiler flow rate. For further
information on water circulation systems see
Potterton Technical Bulletin No. 1 current issue.
BOILER PROTECTION
The provision of pump overrun by a time delay relay
or a thermostat situated in the flow pipe close to the
boiler is essential to remove residual heat from the
boiler, see Fig.21, section 6.
Unions and isolating valves should be fitted to the
flow and return manifolds so that the boiler can be
isolated from the system if the need arises. Your
legal obligations must be adhered to. (i.e. appropriate
safety valves must be fitted).
System Filling
The system must be clean, as debris regress will
damage the boiler.
IMPORTANT: The water level in the cistern or
expansion tank should be minimal on cold
charge to allow expansion without discharge
from the overflow between cold and hot
operating conditions.
SYSTEM WATER QUALITY
High efficiency boiler systems require the water
quality of the system water to be controlled by the
use of inhibitors to maintain a neutral Ph and inhibit
corrosion. Additionally the water system should be
free of leaks to prevent raw water make up which will
dilute any inhibitors, promote corrosion and form lime
scale.
Existing Systems
On existing systems where boilers are being
replaced due to failure then the cause should be
investigated before installing new boilers. This can
normally be achieved by cutting open a failed boiler
section and examination for system debris or
contamination.
Lime scale is a positive indicator of continuous
system water make up due to water loss. Evidence of
magnetite (black sludge) in the system and the
formation of gas in radiators causing air locking is a
positive indicator of corrosion.
Where an old system shows evidence of
contamination then system cleaning should be
carried out before installation of new boilers. The
heating system should be chemically flushed to
remove any lime scale or corrosion and a corrosion
and lime scale inhibitor added. Lime scale descalers
if incorrectly used could cause any remaining system
debris to continue to breakdown and contaminate the
new boiler causing boiler failure.
Advice on system cleaning and suitable products
should be sought from specialist suppliers of system
cleaners such as Fernox or Sentinel.
It is important to note that corrosion inhibitor can only
be used in an attempt to prevent corrosion from
occurring, where a system has an existing corrosion
problem, inhibitors will be ineffective and the system
requires cleaning.
On existing systems where comprehensive descaling
and desludging cannot be carried out then
consideration should be given to separating the new
boiler system from the existing system pipe work by
the use of plate heat exchangers.
New Systems
New pipe work systems should be thoroughly flushed
with a suitable cleaning agent to remove debris and
flux residues before filling. The system water should
be dosed with a suitable corrosion and lime scale
inhibitor.
System Water Monitoring
The system water should be monitored as part of a
maintenance programme to ensure the following.
Raw water make up is not occurring.
Corrosion and lime scale Inhibitors are still active
Water Ph is below Ph 8.5 other wise on systems with
aluminium content, component failures may occur.
SEALED SYSTEMS
General
Potterton Commercial boilers are suitable for use on
sealed systems designed in accordance with BS
6644: 1991 and BS 6880 Part 2. In addition,
reference should be made to the Health & Safety
Executive guidance note PM5 "Automatically
Controlled Steam & Hot Water Boilers.

SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 10
ISIS HE
BOILER ERECTION
A lifetime guarantee is available on this boiler when
erection and commissioning is carried out by the
Potterton Commercial service department and the
system meets with our recommendations. Please
refer to our standard terms and conditions for further
details.
Risk Assessment
Before starting work a risk assessment should be
carried out on the boiler house and its access to
determine and ensure a safe installation and working
environment.
Regardless of the type of activity being assessed, the
principles of risk assessments are the same. The
basic steps are: -
•Classify Activity
•Identify Hazards
•Identify Existing Control Measures
•Determine Risk
•Assess Acceptability of Risk
•Prepare a Control Plan
•Implement Plan
•Review Plan
•Record Results
Manual Handling
Any person or persons moving or lifting the boiler or
any part of the boiler, should be trained in manual
handling techniques and if necessary use suitable
lifting equipment to reduce the risk of injury to
themselves and other people.
Personal Protective Equipment
When undertaking any work you must comply with
the Personal Protective Equipment Regulations
1992.
Confined Spaces
A “confined space” as defined in the Health & Safety
Confined Spaces Regulations 1997 ‘ means any
place, including any chamber, tank, vat, silo, pit,
trench, pipe, sewer, flue, well or other similar space
in which, by virtue of its enclosed nature, there arises
a reasonably foreseeable specified risk.
Precautions should be taken in all areas where by
virtue of its even partially enclosed nature, pose a
reasonably foreseeable specified risk.
Electrical Safety
Working on appliances can be broken down into two
main systems of work.
1) Safe systems of work are adapted for all boiler
maintenance and repair work undertaken on site.
2) The work undertaken does not affect the
electrical safety of the appliance. In particular the
earth connected to the buildings fixed electrical
installation.
In the case of (1) above electrical work should only
be undertaken once the boiler has been isolated from
the electricity supply and confirmed electrically dead.
If this is impractical then suitable precautions must be
undertaken to prevent injury.
In the case of (2) above checks are specified to
identify any abnormality in the electricity supply to the
boiler as well as to confirm that the boiler electrical
connections are reinstated correctly where it is
necessary to disconnect or reconnect any internal
wiring within the boiler.
If it is necessary to disconnect and reconnect the
appliance from the site electrical installation other
than means of a plug and socket then additional
checks shall be undertaken by an approved engineer
to check the earth loop impedance in accordance
with IEE regulations.
Always carry out preliminary electrical safety checks.
All appliances and central heating systems must be
provided with their own means of isolation for safety
purposes especially during installation and
maintenance.
Packaging Details
A detailed breakdown of the contents of the
packages is given in section 7.
Preparation
Preparatory to installation of the boiler a check must
be made to ensure that suitable facilities are
available for off-loading of the individual waterway
sections and conveying them to the boiler room.
Each waterway section weighs approximately 198 kg
and measures 1400mm x 1000mm x 180mm. Ensure
all manual handling techniques are followed.
Particular attention must be paid to ensuring
cleanliness of the boiler room and waterway sections,
dust or moisture may result in imperfect adhesion of
the sealants which are applied during the erection of
the waterways. All tapped holes should be degreased
before making connections.

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 11
ISIS HE
C.O.S.H.H
During the erection procedure there are a number of
items which are subject to the Control Of Substances
Hazardous to Health (C.O.S.H.H) Regulations, and
may require specialist personal protective equipment
(P.P.E) beyond what is normally required. Listed
below are the items subject to the C.O.S.H.H
regulations and the recommended precautions that
should be taken. For a full breakdown of any
substances listed below, please contact the
Commercial Technical Department.
1) Fire Putty 1000 – Wear gloves, overalls and
safety glasses. In the case of an irritation rinse
the affected area with water and wash gently. In
the case of eye contact, flush abundantly with
water. If irritation persists seek medical advice.
2) Brandkitt 1000 – Wear gloves, overalls and
safety glasses. In the case of an irritation rinse
the affected area with water and wash gently. In
the case of eye contact, flush abundantly with
water. If irritation persists seek medical advice.
3) Refractory Ceramic Fibre – Wear gloves and
overalls. In the case of an irritation rinse the
affected area with water and wash gently. In the
case of eye contact, flush abundantly with water.
If irritation persists seek medical advice.
Potterton Commercial Customer
Erection/Assembly Check List
The items listed below have been put together as a
guide to what actions should be completed before the
erection/assembly of a boiler takes place.
I. Site access available for persons carrying
out the proposed work.
II. Site managers/personnel aware that work
will be taking place.
III. Risk assessments carried out on possible
risks that may effect the persons carrying out
the proposed work.
IV. Sections and fittings boxes should be
positioned adjacent to the plinth(s) within the
boiler house prior to persons carrying out the
proposed work attending site. If this is unable
to be done notice prior to attending site
should be given.
V. When boilers are to be stripped and rebuilt,
labour and transport should be provided for
moving the sections from the delivery point to
the final erection point. If this is unable to be
provided notice prior to attending site should
be given.
VI. Sections/casing, etc, should be kept in a
clean and dry area prior to
erection/assembly.
VII. Water should be available.
VIII. A drain off area should be available.
IX. Power should be available.
X. A site representative should be available at
all times.
XI. Clear instructions supplied to the persons
carrying out the proposed work regarding
positioning the boiler.
XII. Fire evacuation procedures, facilities
availability, specific health and safety
information, etc, should be provided.
Items VII to X are essential if boilers require pressure
testing.

SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 12
ISIS HE
Boiler Erection
Waterway Sealing
The waterway sections are sealed at assembly with
silicone rubber compound (Flytande-Packning 260)
and boiler sealing cement (Brandkitt-1000 Palokitti
1000). The waterway sealing grooves must be
cleaned and primed with the primer liquid before
applying the sealant. The primer must be dry before
applying the sealant.
The silicone rubber compound and boiler sealing
cement are supplied in cartridges which should be
loaded into the sealant gun. The primer liquid is
supplied in a bottle and is applied by hand (see
Fig.4).
All sealing grooves must be primed and then filled
with the appropriate sealant to form a bead
approximately 5mm (1/4”) proud. This is obtained by
cutting the correct size aperture in the cartridge
nozzle.
If the nozzle is not cut to approximately 5mm (1/4”)
diameter an incorrect amount of sealant will be
applied. When piercing the sealant tube direct the
nozzle away from the face or hands to minimise the
risk of skin contact.
Before commencing sealing operations sealant and
primer must be checked to ensure that there is
sufficient for the sections being erected (see table 4
for specific quantities). It is advisable to keep spare
cartridges to hand if these are available, particularly
for the boiler cement as some cartridges may contain
a certain percentage of water, which should be safely
drained off before use.
The sealants and sealant gun, which are supplied
with the boiler, are classified as consumables. In
addition to this items standard boiler erection tools
will be required. These should include a crowbar,
heavy duty adjustable wrench and a jack for raising
the firing door.
Erection procedure
Waterway Sections
1. Check off all materials and parts against the
delivery document and boiler parts list (Section 7)
ensuring that a sealant gun and adequate supply
of sealants and primer have been provided.
2. Using a clean rag and paraffin, clean the ‘O’ ring
grooves and sockets on the rear waterway
section.
3. Clean all sealing grooves with a wire brush and
apply the primer liquid using the applicator bottle
provided. Allow the primer to dry. This is
important otherwise the sealant may not stick.
4. Apply a coating of silicone rubber compound
5mm (1/4”) proud around each of the two outer
boiler sealing grooves. See Fig.5
5. Apply a liberal coating of boiler sealing cement
around the inner sealing groove.
6. Support the rear section in its correct position on
the boiler base.
WARNING: THE SECTIONS ARE NOT SELF-
SUPPORTING UNTIL SEVERAL SECTIONS HAVE
BEEN ASSEMBLED TOGETHER. THEREFORE
WHEN STARTING TO BUILD THE BOILER THE
REAR SECTION AND ADJACENT INTERMEDIATE
SECTIONS SHOULD BE ADEQUATLEY
SUPPORTED TO PREVENT INJURY OR DAMAGE.
DUE TO THE WEIGHT OF THE SECTIONS
ASSEMBLY SHOULD BE PERFORMED BY NO
LESS THAN TWO OPERATIVES.

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 13
ISIS HE
TABLE 4 – Section Build Data/Boiler Sealant Details (Giving quantities required per boiler size)
Boiler
Size
Output
kW
Front Section
Pt.No.92210102
Weight 196kg*
Intermediate
Section
Pt.No.92210202
Weight 185kg*
Rear Section
Pt.No.92210301
Weight 200kg
Boiler Cement
(Brandkitt)
Pt.No.922120
No. Rqd.
Silicone Sealant
(Flytande)
Pt.No.922111
No.Rqd.
Silicone
Primer
Pt.No.922119
No. Rqd.
6440 141592
7516 151511 2
8586 161612 2
9670 171713 3
10 762 181815 3
11 840 191916 3
12 925 110 110 18 3
13 1000 111 110 19 3
14 1070 112 111 20 4
15 1172 113 112 21 4
•Weights are approximate
Fig.5 – Waterway Sealing Details
SMOOTH SEALANT
INTO JOINTS AFTER
TIGHTENING UP
SECTIONS
SPRAY PRIMER ON
ALL SEALING
GROOVES, APPLY
SEALANT WHEN
PRIMER IS DRY
“O” RING
“O” RING
GUIDE
BOILER SEALING
CEMENT IN
SINGLE INNER
GROOVE
TIE BOLTS
SILICONE COMPOUND IN
TWO OUTER GROOVES
ENSURE BEAD IS 5mm
PROUND
SEALANT GUN
AND CARTRIDGE
5mm

SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 14
ISIS HE
7. Fit a metal guide onto the top and bottom sockets
in the rear section. These may require tapping
into position using a mallet. Care should be taken
to avoid damaging the guide rings. Fit an “O” ring
over each guide ring.
8. Prepare one face of the first intermediate section
as described in operations 2 – 5 and place in
position for assembly to the rear section. The two
faces that have been prepared utilising the
sealants are now pulled together, this ensures
adequate sealant is throughout the boiler sealing
grooves.
Position the intermediate section directly in front
of the rear section and using a crowbar under the
bottom of the intermediate section, gently lift the
intermediate section slightly upwards and
towards the rear section engaging the two guide
rings.
9. Insert tie bolts through the lower holes into the
upper and lower securing lugs (Fig.6). Tighten
these in turn diagonally to ensure that pulling-up
is equalised so giving an even pressure on both
‘O’ rings. The bolts should be tightened until the
two section faces are drawn together and touch
around the circumference. Ensure all bolts are
fully tightened. A maximum torque of 80 N/m
should be applied.
10. Smooth over the sealing compound, which has
squeezed the section joint and drew to leave a
clean bead, slightly proud. Repeat the procedure
after tightening each section.
11. At this stage, position the waterway sections so
that the flue outlet is aligned with the flue ducting,
if this is already in position. Ensure that the boiler
remains in alignment during assembly of the
waterways.
12. Prepare the sealing grooves and ‘O’ ring guides
of the forward face of the intermediate section
(assembled in operation 8) and the rear face of
the next intermediate section to be fitted.
Proceed as previously described until all
intermediate waterway sections and the front
waterway section have been assembled. The
front waterway section should be installed with
the chamfer pointing towards the front.
Fig.6 – Assembly Tie Bolts
13. Apply primer and silicone rubber compound to
the outer grooves in the rear face of the rear
waterway section and in the grooves on the face
of the flue cover. Offer up the flue cover to the
rear waterway section and secure with nuts and
washers.
Checking for Leaks
1. Fit blanking plates and gaskets to the boiler flow
and return connections but leave a suitable
tapping on top rear connection as it used as an
air vent during filling and testing.
2. Fit a drain cock with a 1” BSP connection to the
flange on the boiler lower front.
3. With all outlets blanked off except the air vent,
connect a water supply to the drain cock and fill
the boiler. When this has been done all air
expelled blank off the boiler vent.
4. The maximum design pressure of the boiler must
not exceed 6 bar and the maximum test pressure
must not exceed 9 bar.
The applied test pressure for assembled boiler
for use on a system designed to operate with a
flow temperature not exceeding 100°C (or 17°C
below the saturated steam temperature at the
design working pressure) shall be 1 ½ times the
designed working pressure for a period of 30
minutes. See BS 779: 1989 for further details.
5. Check carefully for leaks around the ‘O’ ring
joints and section interfaces.
Rear
Section
Tie
Bolts

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 15
ISIS HE
6. Open the drain-cock and drain the boiler.
Remove the blanking plates. Connect the flow
and return 3” – 4” BSP extension turrets to the
boiler (8 – 14 Section only).
Boiler Dismantling
IMPORTANT: THE BOILER SECTIONS ARE NOT
SELF SUPPORTING PARTICULARLY WHEN
THERE ARE ONLY TWO OR THREE SECTIONS
LEFT IN SITU. THEREFORE DURING
DISMANTLING THE SECTIONS SHOULD BE
SUPPORTED TO PREVENT INJURY TO
OPERATIVES.
Dismantling of the boiler is a reversal of the erection
procedure as previously detailed. Care should be
taken during dismantling due to the weight of the
sections and should be carried out by two operators
at a time.
Fitting the Casing
To allow fitting of the electrical and fuel services it will
be necessary to fit casing panels as detailed in the
paragraphs 1 – 12 below, the flue spigot as
paragraph 19 and the burner as detailed under
relevant section. However, the remaining casing and
insulation can, if required, be fitted after construction
has ceased in the boiler house to minimise damage
to the casing.
Fig.7 – Boiler Insulation
1. Fit the insulation strip to the front section as
shown in Fig.7 and secure in position using the
adhesive tape provided.
2. Fit firing door support brackets to the front face of
the boiler, together with four studs and securing
pins. Fit locknuts to the studs on the door hinge
side, see Fig.8
Fig.8. – Fitting Locknuts to Studs
3. Fit the eight hexagonal spacers to the front
section and fit the front boiler casing. This is a
two piece construction using eight machine
screws provided, see Fig.9.
Fig.9. – Front Panel Fixing
Front Door Support
Bracket
Front Insulation Strip
Boiler Body
Insulation
Fixing
Nut
Securing
Pin
Firing Door
Support
Bracket
Lock Nut
Hinge Stud
Fixing Spacer
Two Piece
Front Casing

SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 16
ISIS HE
4. Position the door for the required left or right
hand opening. The two smaller of the four door
fixing holes should be positioned on the hinge
side. Using a jack raise it into alignment with the
door brackets and engage the door holes with
the appropriate hinge studs. Fit and tighten the
fixing screws. See Fig.10.
Fig.10. – Door Fixing
Close the door and fasten it with the door securing
nuts, open it and check the impression of the sealing
grooves in the braiding. There should be a uniform
impression approximately 2mm in depth. Adjust by
means of the fixing nuts to obtain the required
impression. Tighten the fixing nuts and the door
securing nuts diagonally – as you would when
tightening the nuts on a car wheel. This is important
as it ensures an even and adequate seal between
the door and front section. Make sure all locknuts are
fully tightened and forming an adequate seal
between the door and combustion chamber.
5. Fit the door micro switch using the bracket
provided. Close the door and adjust the switch so
that the plunger is depressed by the front panel
when the door is closed. Slots in the bracket
facilitates adjustment, see Fig.11.
6. Fit the firing door insulation panel, see Fig.12.
7. Fit the door casing using the four bolts, nuts and
spacers provided, ensure that the top and bottom
side insulation pieces are placed in position, see
Fig.12
Fig.11 – Door Micro Switch
Fit the firing door casing side panels using the six
screws provided, see Fig.12. When fitting the door
casing ensure that the two side insulation pieces are
inserted.
Fig.12 – Firing Door Casing & Insulation
8. Fit the adaptor plate and gasket, see Fig.13, to
the front waterway section. Screw the thermostat,
thermometer pockets and the pressure gauge
self isolating fittings into the tapings in the
adaptor plate.
9. Fit the control panel housing to the front casing
using the four screws provided, see Fig.13.
Use Jack or
Wooden Props
Micro
Switch
Mounting
Bracket
Control
Panel
Flexible
Conduit

POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PAGE 17
ISIS HE
10. Fit the control panel using the four screws
provided ensuring that the thermostat and
thermometer phials are connected into their
pockets and the pressure gauge sensing head to
the isolating fitting.
Fig.13 – Control Panel
11. Insulate the main boiler body ensuring that the
insulation is drawn down equally on both sides to
the base of the boiler. On larger boilers, where
two pieces of insulation are provided, tape the
insulation joint with the tape provided.
12. Insulate the rear section using the insulation
panels provided and mount the rear casing
panels using the three bolts and washers and
secure the two panels together using the screws
provided, see Fig .14.
Fig.14 – Rear Casing
13. Mount the rear lower panels.
14. Mount the side rails, Fig.15. On 6 section boilers
these are omitted. On larger boilers there are
eight rails provided (two for each corner) which
should be drilled and fixed together to obtain the
correct overall case dimension, (see Table 1.).
Fig.15 – Boiler Side Rails
15. Mount the side casing panels starting from the
rear of the boiler. Larger boilers will have
additional side panels, see parts list. It will be
necessary to drill fixing holes for these additional
panels to compensate for erection tolerances.
Ensure side case panels are level from front to
back before drilling, see Fig.16.
Fig.16 – Boiler Side Panel Fixing
16. Drill and secure the side panel to the front panel
using the screws provided, see Fig.17.
17. Mount the top panels as shown in Fig.11. Drill
and secure in position using the screws provided.
Adaptor
Plate
Pressure
Gauge
Isolating
Fitting
Thermometer
Pocket
Data Plate
Control
Panel
Housing
Control
Panel
Thermostat
Pocket
Rear Casing Panels
Flue Spigot
Rear Clean Out
Covers
Position and secure
using a drill to suit
boiler size
Side Rails
Position side casing
and fasten in
position