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.