Potterton PROFILE LPG 100e User guide

LPG 50e, 60e, 80e & 100e fanned
balanced flue gas fired boilers
THIS APPLIANCE IS FOR USE WITH PROPANE GAS ONLY
Installation and Servicing Instructions
LEAVE THESE INSTRUCTIONS ADJACENT TO THE APPLIANCE

IMPORTANT
This appliance must be installed and serviced by a competent person as
stated in the Gas Safety (Installation and Use) Regulations 1984. Profile
Prima LPG boilers have been designed to comply with the requirements of
BS 5258 Part 11986 and BS 6332 Part 11983. 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 Health and Safety Information Back Page
Control Systems, Pipework and
Wiring Guide Supplied in
User’s Instructions Literature Pack
GENERAL - Page 2
Profile Prima LPG boilers are fully automatically controlled
wall mounted fan powered balanced flue appliances, using a
cast iron heat exchanger and are available in four outputs.
15.1 kw (51,500 Btu/h r), 18.88kw (64,400 Btu/hr), 23.4 kw
(80,000 Btu/hr), 29.3 kw (100,000 Btu/hr).
The boilers which are designed to provide domestic hot
water and/or central heating must be used on INDIRECT
FULLY PUMPED systems only, which may be sealed or
open vented.
The boilers can be supplied with either of the following types
of flue system.
PRIMA LPG 100e MODEL ONLY
1 metre horizontal flue system which provides a maximum
flue length of 955mm (37in).
Vertical flue system which allows the flue to pass through a
flat roof and terminate at a maximum height of 980mm (38in)
measured from the top of boiler case.
PRIMA LPG 50e, 60e, & 80e Models only
Standard horizontal flue system which is suitable for a
wall thickness of 100mm (4in) to 510mm (2Oin).
2 metre horizontal flue system which provides a maximum
flue length of 1955mm (77in).
Vertical flue system which allows the flue to pass through a
flat roof and terminate at a maximum height of 1980mm
(78in) measured from the top of 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 51 0mm (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 Kit, located on top of the boiler and is
designed to conceal the pump, and/or any motorised valves
installed above the boiler. (Note: Pump cannot be fitted
above the boiler if the vertical flue kit is used).
Terminal Wall Plate, where necessary can be fitted to the
outside wall face to improve the appearance, after making
good around the terminal.
PART Nos
50e 60e 80e 100e
Standard Flue System 225175 225176 225176 N/A
1 metre Flue System N/A N/A N/A 225289
2 metre Flue System 225178 225179 225179 N/A
Vertical Flue System 225280 225281 225282 225162
Terminal Wall Plate 212306 212280 212280 212280
Terminal Guard 205792 205792 205792 413246
Internal Fitment Kit 225183 225I84 225184 225184
Pump Cover Kit 225181 225181 225132 225182

OPTIONAL EXTRAS - Page 3
The following range of Potterton system controls are also
available and further information will be provided on
request.
Electronic Programmer E.P. 2001, E.P. 3001, E.P.
4001, E.P. 6000.
Programmable Electronic Thermostat PET 1.
ACCESSORIES
Thermostatic Radiator Valve Myson
Electronic Cylinder Thermostat PTT2
Electronic Room Thermostat PRT2
Spring Return Zone Valve PMV2
Spring Return Diverter Valve PMV3
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.
B56798, BS5440 Part 1, BS 5482 Part 1
B55440 Part 2 BS5449 Part 1
B55546 B54814 B56891
BUILDING REGULATIONS 1985.
MODEL WATER BYELAWS.
BRITISH GAS PUBLICATION DM2.
GAS SAFETY (INSTALLATION AND USE) REGULATIONS
1984.
BUILDING STANDARDS (SCOTLAND)
REGULATIONS.
BOILER DIMENSIONS - Page 3
FIG. 1
Boiler 50e 60e 80e 100e
Dimension ‘A’ 350 350 425 425
(MM) ‘B’ 110 110 150 150
‘C’ 103 103 143 143
‘D’ 90 107 107 107
Flow/Return 22mm 22mm 28mm 28mm
Connections Copper Copper Copper Copper
*NOTE
IF PIPEWORK IS TO BE RUN DOWN THE BACK OF THE BOILER
THE NORMAL CLEARANCE OF 25mm BETWEEN THE REAR OF
THE BOILER AND WALL CAN BE INCREASED TO 35mm IF DESIRED
BY INVERTINGTHE BOILER MOUNTING PLATE DURING
INSTALLATION
Dimensions in brackets apply when the mounting plate is inverted).
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
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 BS5482 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 DM2 ‘Guide for Gas Installations in Timber
Framed Housing’.
Clearances Around the Boiler
The following minimum clearances must be maintained after
installation, for correct operation and servicing of the boiler:
61 0mm (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
PROFILE PRIMA AIR VENT AREAS
in² cm²
50e 27 174
60e 33 213
80e 43 277
100e 54 349
If the openings draw air from outside the building the free
areas may be halved. Refer to BS 5440 Part 2 1976 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 information
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 1978 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
A. DIRECTLY BELOW AN OPENABLE WINDOW, AIR
VENT, OR ANY OTHER VENTILATION OPENING 300
B. BELOW GUTTER, DRAIN/SOIL PIPE 75
C. BELOW EAVES 200
D. BELOW BALCONY OR CAR PORT ROOF 200
E. FROM VERTICAL DRAIN PIPES AND SOIL PIPES 75
F. FROM INTERNAL OR EXTERNAL CORNERS 300
G. ABOVE ADJACENT GROUND OR BALCONY LEVEL 300
H. FROM A SURFACE FACING THE TERMINAL 600
I. FACING 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
FIG. 4 FLUE SETTINGS
MAXIMUM
LENGTH ‘X’
1 METRE FLUE
SYSTEM 955mm
100e MODEL ONLY (37in)
STANDARD FLUE
SYSTEM
50e, 60e, & 80e 510mm
MODELS ONLY (20in)
2 METRE FLUE
SYSTEM
50e, 60e, & 80e 1955mm
MODELS ONLY (77in)
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 least0.75mm2 in accordance with BS
6500. Table 16.The supply to the boiler and its associated
equipment
should be controlled by a 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 (100ft)
Minimum working head 150mm (6in)
Gas supply pressure 20 mbar
Maximum flow temperature 82°C
Electricity supply 240v—5OHz fused at 3A
Internal Fuse Type T1A
Power Consumption 80 Watts (excluding pump)
Gas supply connection Rc. ½ (½in BSP female)
50e & 60e Models 80e & 100e Models
Appliance lift weight (mm) 26.0kg (57.3lbs) 33.5kg (73.871bs)
Appliance weight installed 37.1kg (81 .8Ibs) 46.4kg (102.3lbs)
Water content 2.0 litre (0.44 gal) 2.4 litre (0.53 gal)
Flow/Return connections 22m copper 28mm copper

TECHNICAL DATA - Page 7
BOILER
SIZE INJECTOR SIZE GAS RATE at 95.0 MJ/m3
(2500 Btu/W)
m3/h (W/h)
INPUT
kW (Btu/h) OUTPUT kW (Btu/h) BURNER PRESSURE
mbar (in wg)
SUPPLY
PRESSURE
mbar (in wg)
50e 2.2mm 0.73 (25.8) 18.88 (64,400) 15.1 (51,500) 35.7 (14.3) 37 (14.8)
60e 2.4mm 0.89 (31.4) 23.0 (78,500) 18.4 (62,800) 35.7 (14.3) 37 (14.8)
80e 2.7mm 1.13 (40.0) 29.31 (100,000) 23.45 (80,000) 34.1 (13.7) 37 (14.8)
100e 3.0mm 1.42 (50.0) 36.64 (125,000) 29.3 (100,000) 33.2 (13.3) 37 (14.8)
CIRCULATION PUMP SELECTION
The resistance through the heat exchanger when operating
with a water flow rate producing an 11 0C temperature rise
at maximum boiler output are shown in TABLE 2. If other
controls, such as three-position valves are used in the
system, the resistance through them, quoted in their
manufacturer’s literature must be taken into account The
pump may be fitted on either the flow or return and MUST be
wired directly to the boiler terminal block, see FIG. 23. 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.
TABLE 2
FIG. 5 PRESSURE LOSS ACROSS BOILER

TECHNICAL DATA - Page 8
The System
The boiler must be used on INDIRECT FULLY PUMPED
systems only, which may be sealed or open vented.
The system should be designed so that the maximum
static head does not exceed 30.5m (100ft) and a
minimum of 150mm (6in). See FIG 6.
On all systems the pump should be wired to the boiler
terminal block, it will then be controlled by the pump over-run
thermostat. This will ensure that the pump will continue to
run after boiler shut down if the water temperature is high,
thus preventing 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 from within the boiler.
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
22mm 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.
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.
SEALED SYSTEMS
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 (6Olbf/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 BS4814 Part 1 shall
be fitted close to the inlet side of the pump. The connecting
pipework should not be less than 15mm (1/2in 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
82°C.
The vessel size can now be determined from the following
table where V=System volume in litres
Vessel Charge Pressure(bar) 0.5 1.0
Initial System Pressure (bar) 1.0 1.0
Expansion Vessel Volume (litres) V x 0.11 V x 0.087
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 (5lbf/in2) in excess
of safety valve setting. Single feed indirect cylinders are not
suitable for sealed systems.
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 by
using the mains top up method or a remote automatic
pressurisation and make-up unit as illustrated in FIG. 7
METHODS 1 and 2.
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.
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

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 1984. For Health and Safety
Information see back page.
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
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. 8 TEMPLATE FIG. 9 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. 10a SIDE FLUE FIG. 10b 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. 11 AIR/FLUE DUCT ASSEMBLY
1. Slide rope sealing ring on to air duct.
2. Engage the terminal on to the ends of the inner flue
duct and outer air duct with its discharge vanes
arranged to deflect the flue products in the desired
direction. Press terminal 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
FIG. 12 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.

INSTALLATION INSTRUCTIONS - Page 13
FIG. 13 PREPARING THE 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
controls cover, see FIG 13.
Undo securing screw, pull controls cover forward 10 mm,
lower to release from four side fixings and pull forward clear
of thermostat knob.
Remove the door by undoing the lower fixing screws and lift
door off the two upper hinge brackets.
Disconnect the two flexible tubes from the flue elbow.
Remove thumb screw securing the flue elbow and remove
elbow by sliding forward to disengage it from its rear
retaining flange.
NOTE
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.
The boiler may now be lifted onto its mounting bracket or if
desired the appliance liftweight can be further reduced by
removing the fan/fluehood assembly also the burner/ gas
control assembly as follows.
1. Removing fan/fluehood assembly.
Disconnect the fan supply and earth leads from the
connector adjacent to the fan. Remove the two wing
nuts securing the flue hood to the heat exchanger. Uft
out fan/fluehood assembly.
2. Removing burner/gas control assembly.
Remove the screws securing the combustion chamber
front panel and remove panel. Unplug the electrical
supply leads for the gas control valve from the control
box.
Remove the screw securing the gas control valve to its
support bracket.
Disconnect electrode lead from electrode. Remove two
screws securing the burner assembly to the bottom of
the boiler case and lift out the burner/gas control
assembly.

INSTALLATION INSTRUCTIONS - Page 14
LIFTING THE BOILER
Lift the boiler onto its mounting bracket.
FIG. 14
Locate the studs on the air duct flange through the boiler
casing and secure using four wing nuts (accessory pack F).
FIG. 15 TRANSPORTATION FOOT
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 rearwall can be
corrected using the adjustment screws at the rear of the
boiler. See FIGS. 15 & 16.
FIG. 16 SECURING BOILER FIG. 17
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.
If the fan/fluehood assembly or burner/gas control assembly
were removed to reduce the appliance lift weight, refit them
to the boiler. Reassembly is the reverse of removal. When
refitting the burner/gas control assembly ensure that the
locating pin on the rear of the burner engages correctly into
the rear support bracket.
When refitting the fan/fluehood assembly ensure that the
rear of the fluehood is correctly located beneath retaining
flange. See FIG. 17.

INSTALLATION INSTRUCTIONS - Page 15
FIG. 18 FLUE ELBOW EXTENSION
When side fluing, slide the elbow extension onto the elbow,
push on fully and align the hole for securing screw with
arrow on elbow. Engage the screw from accessory pack ‘C’
into the pre-.drilled hole in 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.
FIG.19 LOCATION OF PRESSURE SENSING TUBES
Slide the flue elbow into the flue duct, ensure that the sealing
gasket is in place and the elbow is correctly located beneath
the retaining flange at the rear. See FIG.19.
Secure elbow using thumb screw previously removed.
Reconnect flexible tubes to elbow.
ENSURE THEY ARE NOT KINKED.
The tubes are supplied at the length required for left hand
flue outlet. When using rear or right hand flue outlets, to
avoid kinking, the tubes should be shortened by 150mm. A
band around the tube indicates the cutting point.
NOTE
Red tube connects the front aluminium tube to the lower
connection on the 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 both of the thermostat bulbs
from the flow pipe before soldering.
A drain off tap should be installed close to the boilerif it is in
a low point of the system. Connect the gas supply pipe to the
inlet of the gas cock. Ensure the gas cock is in a position
where it can be easily operated when the controls cover is
removed.

INSTALLATION INSTRUCTIONS - Page 16
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.
FIG. 21 PRINCIPLE OF WIRING
FIG. 22 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. 21.
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.
FIG. 22 ACCESS TO THE BOILER ELECTRICAL Remove
packaging from rear of the control box.

INSTALLATION INSTRUCTIONS - Page 17
FIG. 23 ROUTING OF ELECTRICAL WIRING
Following the pump manufacturer’s instructions connect the
pump supply wires to terminals marked PUMP LN on the
boiler terminal block. Route the cable through the plastic bush in
the rear of the control box as illustrated in FiG. 23 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. 23 and
connect it to the boiler input terminals as follows:
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 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 infill 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 (accessory pack G)
positioned as illustrated.
FIG. 24

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 1987.
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 ± 0.3 bar of the preset lift pressure of 3
bar. Release water to attain the correct cold fill pressure, and
set the indicator on the water gauge to this value.
All Systems
The whole of the gas installation including the meter should
be inspected and tested for soundness and purged in
accordance with the recommendations of BS 6891.
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. 23.
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 electricity 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. 23.
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.
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.
After installation of the appliance, preliminary electrical
system checks must be carried out. 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. 30
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. 25 MAIN BURNER PRESSURE ADJUSTMENT
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. 29.
If the pilot flame is not as illustrated, remove and clean the
pilot as described in the Servicing Instructions Section 4,
PILOT BURNER, Page 22.
Boiler Thermostat
At its minimum and maximum settings, the thermostat
should control the water flow temperature at approximately
550C—820C (1300F—1800 F).
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.
Pump Over-Run Thermostat
Will keep the pump running after the boiler has shut down,
as long as the water temperature within the boiler is above
80°C.
The thermostat is preset and no adjustment is possible.
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
FIG. 26 FUNCTIONAL FLOW DIAGRAM
HONEYWELL
FIG. 27 BOILER WIRING DIAGRAM