Potterton Prorile Prima 30e User guide

Supplied By www.heating spares.co Tel. [phone]
30e, 40e, 50e, 60e, & 80e, fanned balanced flue
gas fired boilers
THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20) ONLY
Installation and Servicing Instructions
LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.

Supplied By www.heating spares.co Tel. [phone]
GAD (90/396/EEC)
POTTERTON PROFILE 30e G.C. No. 41 .605.39
POTTERTON PROFILE 40e G.C. No. 41 .605.40
POTTERTON PROFILE 50e G.C. No. 41 .605.41
POTTERTON PROFILE 60e G.C. No. 41 .605.42
POTTERTON PROFILE 80e G.C. No. 41 .605.43
IMPORTANT This appliance must be installed and serviced by a competent person as stated in the Gas Safety (Installation
and Use) Regulations 1994.
Profile boilers are certified for safety, it is therefore 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 certificate
and 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
Potterton Profile boilers are fully automatically controlled
wall mounted fan powered balanced flue appliances, using
a cast iron heat exchanger and are available in five outputs
ranging from 5.86-23.44kW (20,000-80,000 Btu/h).
The boilers which are designed to provide domestic hot
water and/or central heating must be used on INDIRECT
hot water systems only. The cast iron heat exchangers are
suitable for use on open vented gravity domestic hot
water/pumped central heating systems or fully pumped
systems which may be sealed or open vented.
All boilers can be supplied with either of the following types
of flue system:
1) Standard horizontal flue system suitable for wall
thickness of 100mm (4 in.) to 510mm (20 in.).
2) 2 metre horizontal flue system which provides a
maximum flue length Of 1955mm (77 in.).
3) Vertical flue system which allows the flue to pass
through a flat roof and terminate at a maximum height
of 1980mm (78 in.) measured from the top of the boiler
case.
OPTIONAL EXTRAS - Page 2
The following are kits available as optional extras:—
Internal Fitment Kit, which is suitable for a maximum wall
thickness of 51 0mm (20 in.) is to be used where access to
the outside wall is impracticable.
Pump Cover Kits, located on top of the boiler and
designed to conceal the pump, and/or any motorised valves
installed above the boiler. (Note: 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.
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.
P.I.L. PART Nos.

Supplied By www.heating spares.co Tel. [phone]
ACCESSORIES - Page 3
The following Potterton Myson controls are recommended
for use with your boiler:-
Electronic Programmer EP2001, EP3001, or EP6000
Cylinder Thermostat PTT2 or PTT1 00
Room Thermostat PRT2 or PRT1 00
Frost Thermostat PRT1 00 FR
Motorised Zone Valve M5V222 or M5V228
Motorised Diverter Valve M5V322
Thermostatic Radiator Valve
Data sheets describing these products are available on
request.
INSTALLATION DATA - Page 3
The installation of the boiler must be in accordance with the
latest relevant requirements of the Gas Safety (Installation
and Use) Regulations, 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.
BS6798, B55440 Part 1
B55440 Part 2 B55449 Part 1
B55546 B5481 4. B56891.
BUILDING REGULATIONS.
MODEL WATER BYELAWS.
BRITISH GAS PUBLICATION DM2.
GAS SAFETY (INSTALLATION AND USE)
REGULATIONS.
BUILDING STANDARDS (SCOTLAND)
REGULATIONS.
BOILER DIMENSIONS - Page 3
R.c½
*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 INVERTING THE 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
boiler may be installed in any room, although 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.

Supplied By www.heating spares.co Tel. [phone]
SITE REQUIREMENTS - Page 4
FIG. 2 GENERAL ARRANGEMENT

Supplied By www.heating spares.co Tel. [phone]
SITE REQUIREMENTS - Page 5
Where the installation of the boiler will be in an unusual
location, special procedures may be necessary and BS 6798
gives detailed guidance on this aspect.
Ensure that the gas supply pipe and meter are large enough
for this appliance and any others that may be run off the
same meter. Reference should be made to B56891
Boiler Mounting Surface
The boiler must be mounted on a flat wall, which may be of
combustible material and must be sufficiently robust to take
the weight of the boiler. The requirements of the local
authorities and the Building Regulations must be adhered to.
IMPORTANT NOTICE:
TIMBER FRAMED HOUSES
If the appliance is to be fitted in a timber framed building, it
should be fitted in accordance with British Gas Publication
‘Operational Procedures for Customer Service’ Part 19. If in
any doubt, advice should be sought from the local region of
British Gas.
Clearances Around the Boiler
The following minimum clearances must be maintained after
installation, for correct operation and servicing of the boiler:
610mm (2 ft) at the front of the boiler
5mm (0.2 in) each side of the boiler
50mm (2 in) at the top (measured from the top of the boiler
case), except where the optional extra pump cover is to be
fitted, when 178mm (7 in) should be allowed.
100mm (4 in) at the bottom of the boiler.
Additional clearances to these are required during
installation for lifting the boiler and 127mm (5 in) is required
at the top of the boiler for access to the pipe connections.
Ventilation
If the boiler is to be installed in a confined space such as a
cupboard, the space will need ventilating. Openings must be
provided at the top and bottom of the Cupboard each of
which should have a free area as shown in TABLE 1. Further
details for installation of a boiler within a compartment are
given in BS 6798.
TABLE 1 AIR VENT AREAS
PROFILE in2cm2
30e 16 103
40e 21 135
50e 26 170
60e 32 206
80e 43 277
If the openings draw air from outside the building the free
areas may be halved. Refer to BS 5440 Part 2 for further
guidance.
Balanced Flue Terminal and Ducting
The fresh air inlet and flue ducts can be run from either the
left, right, rear or top of the boiler to a miniature terminal on
the outside of the building.
The minimum spacings from the terminal to obstructions and
ventilation openings are shown in FIG. 3. For 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 for further guidance.
FIG. 3 THE SITING OF BALANCED
FLUE TERMINALS
INFORMATION RELATING TO VERTICAL FLUING IS
PROVIDED IN THE PACK CONTAINING THE VERTI-CAL
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 be fitted 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.
POSITION MINIMUM DISTANCE
mm
A. DIRECTLY BELOW AN OPENABLE
WINDOW, AIR VENT, OR ANY OTHER
VENTILATION OPENING. 300
B. BELOW GUTTER, DRAIN/SOIL PIPE 25
C. BELOW EAVES 25
D. BELOW A BALCOY OR CAR PORT ROOF 25
E. FROM VERTICAL DRAIN PIPES AND
SOIL PIPES 75
F. FROM INTERNAL OR EXTERNAL CORNERS 25
G. ABOVE ADJACENT GROUND OR BALCONY
LEVEL 300
H. FROM A SURFACE FACING THE TERMINAL 600
I. FACING TERMINALS 1,200
J. FROM OPENING (DOOR/WINDOW) IN
CARPORT INTO DWELLING 1,200
K. VETICALLY FROM A TERMINAL ON
THE SAME WALL 1,500
L. HORIZONTALLY FROM A TERMINAL ON
THE SAME WALL 300
M. ADJACENT TO OPENING 150

Supplied By www.heating spares.co Tel. [phone]
SITE REQUIREMENTS - Page 6
ALL MODELS REAR OR SIDE FLUEING
FIG. 4 FLUE LENGTHS
MAXIMUM
LENGTH ‘X’
STANDARD FLUE
SYSTEM 510mm (20in)
1 METRE FLUE
SYSTEM 955mm (37in)
ELECTRICITY SUPPLY
A 240 volts -~ 50Hz, single phase electricity supply fused to
3 amperes, must be provided in accordance with the latest
edition of the I.E.E. Wiring Regulations and any other local
regulations that may apply. The current rating of the wiring
to the boiler must exceed 3 amperes and have a cross
sectional area of at least 0.75mm2 in accordance with
B56500 Table 16.
The supply to the boiler and its associated equipment should
be controlled by an exclusive 3A fused double pole switch
(having at least 3mm contact separation in both poles) so that
complete isolation from the supply can be achieved to enable
servicing work to be carried out in safety.
TECHNICAL DATA
Maximum working head 30.5m (100 ft) Gas supply connection Rc. 1/2 (i/2in BSP
Minimum working head on Female)
Fully Pumped systems 305mm (1 ft)
Minimum circulating head Water Content Models 30e, 40e
on Gravity systems 1.2m (4ft) 6.0 litre (1.32 gal)
Gas supply pressure 20mbar Models 50e, 60e &
Maximum Flow temperature 820C80e
Electricity supply 240v~-50Hz fused 6.5 litre (1.43 gal)
at 3A
Power consumption 80 watts Appliance Weight-installed Models 30e, 40e
(excluding pump) Appliance Weight-lift 52kg (115 Ibs)
Flow/Return connection 22mm copper on 46kg (101 Ibs)
30e, 40e models
28mm copper on Appliance Weight-installed Models 50e, 60e &
50e, 60e, 80e Appliance Weight-lift 80e
models 62kg (137 Ibs)
53kg (117 Ibs)

Supplied By www.heating spares.co Tel. [phone]
SITE REQUIREMENTS - Page 7
BOILER INJECTOR GAS RATE INPUT OUTPUT BURNER PRESSURE
SIZE SIZE m3/h (ft3/h) kW(Btu/h) kW(Btu/h) mbar in wg
Min 2.9mm 0.73(25.8) 7.83(26702) 5.86(20000) 5.9 2.4
30e 0.9(31.95) 9.69(33068) 7.33(25000) 7.8 3.1
Max 1.05(36.92) 11.20(38217) 8.79(30000) 10.4 4.2
Min 3.1mm 1.09(38.34) 11.63(39682) 8.79(30000) 8.4 3.4
40e 1.24(43.8) 13.29(45336) 10.26(35000) 10.8 4.3
Max 1.39(49.23) 14.93(50955) 11.72(40000) 13.4 5.4
Min 3.5mm 1.39(50.23) 15.24(52000) 11.72(40000) 8.7 3.5
50e 1.58(55.74) 16.90(57692) 13.19(45000) 11.0 4.4
Max 1.75(61.84) 18.76(64000) 14.65(50000) 12.8 5.1
Min 3.8mm 1.79(63.09) 19.14(65300) 14.65(50000) 10.3 4.1
60e 1.94(68.55) 20.79(70950) 16.12(55000) 12.0 4.8
Max 2.11(74.4) 22.57(77000) 17.58(60000) 14.0 5.6
Min 4.4mm 2.18(77.1) 23.39(79800) 17.58(60000) 8.5 3.4
80e 2.5 (88.4) 26.82(91503) 20.52(70000) 11.0 4.4
Max 2.82(99.71) 30.25(103200) 23.45(80000) 14.0 5.6
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. 24. It
must be fitted with two isolating valves which are positioned
as close to the pump as possible. Closing of any valve must
always leave the open vent unobstructed.
TABLE 2
FIG. 5 PRESSURE LOSS ACROSS BOILER

Supplied By www.heating spares.co Tel. [phone]
SITE REQUIREMENTS - Page 8
The System
The boiler must be used on INDIRECT hot water systems only. It is
suitable for use on open vented gravity domestic hot water/pumped
central heating systems or, fully pumped systems which may be
sealed or open vented.
The system should be designed so that the maximum static head
does not exceed 30.5 m (100 ft) and a minimum on fully pumped
systems of 305 mm (1 ft). See FIG. 6.
Gravity domestic hot water circuits should have a minimum
circulating head of 1.2 m (4ft). See FIG. 8.
To ensure optimum boiler performance on both gravity hot water
and fully pumped systems a change-over switch is incorporated in
the boiler control box. The boiler is supplied with the switch set for
sealed or open vented fully pumped systems.
If the boiler is to be used on a system with gravity hot water the
switch should be set at the GRAVITY position. In addition the bulb
of the overheat thermostat should be repositioned as shown in
FIG. 21.
To prevent reverse circulation in the gravity circuit when the pump
is running an injector disc is provided to form an injector tee at the
return connection on the boiler. See FIG. 20.
On all systems the pump should be wired to the boiler terminal
block. To prevent nuisance operation of the overheat thermostat, it
is important that where electrically operated zone valves are used
the boiler is wired so it does not cycle when the zone valves are
closed. Also, systems fitted with controls that close both hot water
and central heating circuits while the boiler is still hot, must be
fitted with a by-pass circuit to dissipate the residual heat within the
boiler.
Further information on by-pass arrangements is provided in later
notes and illustrations.
Drain off taps should be fitted in the pipework close to the boiler
and in the low points of the system.
Note: Although the system can be emptied using the drain off taps
installed in the pipework around the system, to empty the boiler it is
necessary to remove the drain off cap positioned within the boiler
case. See FIG. 2.
Combined Gravity Hot Water Pumped Central Heating
Systems. Where a cylinder thermostat and zone valve is used to
control the temperature of the hot water it is recommended that a
by-pass be installed in the gravity circuit. A suggested method of
doing this is shown in FIG. 8 where the bathroom radiator is
connected into the gravity circuit and is fitted with two lockshield
valves. Mechanically operated thermostatic domestic hot water
temperature control valves which allow the boiler to operate when
the valve is closed or partially closed MUST NOT BE FITTED.
Fully pumped Systems
With the change-over switch in the control box set at the FULLY
PUMPED position, the pump will be controlled by an over-run
thermostat. This will ensure that the pump will continue to run after
boiler shut down if the water temperature in the boiler is high, thus
preventing nuisance operation of the overheat thermostat.
If a three port diverter valve is used as shown in FIGS. 6, 7 a by-
pass is not necessary since one circuit is always open.
Where a pair of two port valves are used, a by-pass is
necessary. The total length of the by-pass circuit taken from the
boiler connections should be greater than 4 metres of 22 mm pipe.
It should be fitted with a lockshield valve and be adjusted to
maintain a minimum flow through the boiler of 4.5 litres/mm (1
gal/mm) see FIGS 6, 7.
Systems fitted with controls which allow the boiler to operate when
both the hot water and central heating circuits are closed i.e.
mechanically operated thermostatic control valves, must be fitted
with a by-pass circuit capable of:—
1. Dissipating a minimum of 1 kW (3400 Btu/h)
2. Maintaining a minimum water flow through the boiler of 9
litres/mm (2 gal/mm).
A suggested method of meeting these requirements by using a
bathroom radiator fitted with two lockshield valves is shown in
FIGS. 6, 7.
Additional system information can be found in the Control Systems,
Pipework and Wiring Guide.
SEALED SYSTEMS (FULLY PUMPED)
Installation
The installation must comply with the requirements of BS 6798 and
BS 5449 Part 1. The B.G. publication “British Gas Specification for
Domestic Wet Central Heating Systems” should also be consulted.
Safety Valve
A non adjustable spring-loaded safety valve, preset to operate at 3
bar (451bf/in2) shall be used. It must comply with BS 6759 Part 1
and include a manual testing device. It shall be positioned in the
flow pipe either horizontally or vertically upwards and close to the
boiler. No shut-off valves are to be placed between the boiler and
the safety valve. The valve should be installed into a discharge
pipe which permits the safe discharge of steam and hot water such
that no hazard to persons or damage to electrical components is
caused.
Pressure Gauge
A pressure gauge incorporating a fill pressure indicator, covering
the range 0-4 bar (60 lbf/in2) shall be fitted to the system. It should
be connected to the system, preferably at the same point as the
expansion vessel. Its location should be visible from the filling
point.
Expansion Vessel
A diaphragm type expansion vessel to B54814 Part 1 shall be fitted
close to the inlet side of the pump. The connecting pipework
should not be less than 15 mm (½ in nominal). Pipework
connecting the expansion vessel should not incorporate valves of
any sort. Methods of supporting the vessel are supplied by the
manufacturer. The nitrogen or air charge pressure of the expansion
vessel shall not be less than the hydrostatic head, (height of the
top point of the system above the expansion vessel). To size the
expansion vessel it is first necessary to calculate the volume of
water in the system in litres. The following volumes may be used
as a conservative guide to calculating the system volume.
Boiler Heat Exchanger: 6.5 litres
Small Bore Pipework: 1 litre per kW of
system output
Micro Bore Pipework: 7 litres
Steel Panel Radiators: 8 litres per kW of
system output
Low Water Capacity Radiators: 2 litres per kW of
system output
Hot water Cylinder: 2 litres

Supplied By www.heating spares.co Tel. [phone]
SITE REQUIREMENTS - Page 9
If the system is extended, the expansion vessel volume may
have to be increased unless previous provision has been
made for the extension. Where a vessel of the calculated
size is not available, the next available larger size should be
used.
The boiler flow temperature is controlled at approximately
820C.
The vessel size can now be determined from the following
table where V=System volume in litres.
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 (51 bf/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

Supplied By www.heating spares.co Tel. [phone]
SITE REQUIREMENTS - Page 10
FIG 7. FULLY PUMPED SEALED SYSTEM
FIG 8. OPEN VENTED GRAVITY DOMESTIC HOT
WATER AND PUMPED CENTRAL HEATING SYSTEM

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

Supplied By www.heating spares.co Tel. [phone]
INSTALLATION INSTRUCTIONS - Page 12
CUTTING AIR/FLUE DUCTS
FIG. 11a SIDE FLUE FIG. 11b REAR FLUE
1. Measure from outside face of wall to the side of boiler
casing reference line (dimension ‘x’).
2. Take air/flue duct assembly and measuring from the
flanged end, mark and cut the outer duct and inner flue
duct to dimension ‘x’ plus 20mm. Ensure that both
ducts are cut squarely.
1. Measure wall thickness (dimension ‘Y’).
2. Take air/flue duct assembly and measuring from the
flanged end, mark and cut the outer air duct and inner
flue duct to dimension ‘Y’, plus 45 mm. Ensure that
both ducts are cut squarely.
NOTE
Cutting length remains the same for minimum or
maximum clearance at the rear of the boiler.
FIG. 12 AIR/FLUE DUCT ASSEMBLY
NOTE: During assembly the seam in the air duct should be
so arranged that when installed, the seam in the duct will be
uppermost.
1. Slide rope sealing ring on to air duct.
2. Engage the terminal on to the ends of the inner flue
duct and press fully home.
3. Engage four screws from accessory pack ‘C’ into the
pre-drilled holes in the terminal and screw fully home.
These screws which are self drilling will pierce the air
duct and secure the terminal to air duct.
On models 30e, to 50e, it is necessary to drill four pilot
holes in the air duct.

Supplied By www.heating spares.co Tel. [phone]
INSTALLATION INSTRUCTIONS - Page 13
FIG. 13 SECTIONAL VIEW OF AIR/FLUE
DUCT ASSY THROUGH WALL
4. Protect duct where it is likely to come into contact with
mortar by using adhesive tape provided (accessory pack
E).
5. Insert the assembly into the wall sliding the rope sealing
ring along the air duct into the flue sealing collar. Bend
the six tabs on flue sealing collar inwards to retain the
rope sealing ring. Ensure air duct flange studs do not
obstruct lifting of boiler onto mounting bracket.
FIG. 14 PREPARING BOILER
The controls cover should have been removed when
unpacking the boiler, if not remove controls cover by opening
the door covering the securing screw on the underside of the
controls cover, see FIG. 14. Undo securing screw, pull
controls cover forward 10mm, lower to release from the four
side fixings and pull forward clear of the thermostat knob.
Remove door by undoing the two lower fixing screws and lift
door off the two upper hinge brackets.
Remove the screws securing the combustion chamber front
panel and remove panel.
Disconnect the fan supply leads from the connector adjacent
to the fan. Leaving in place the three screws identified with a
red circle or adjacent ‘F’ mark in fan
plate. Remove the remaining screws securing the fan
mounting plate and remove the mounting plate complete
with fan.
Disconnect the two flexible tubes from the flue elbow.
Remove the four brass securing nuts and lift off the flue
elbow, taking care not to damage the gasket.
NOTE:
If side fluing, loosen the two brass securing nuts beneath the
flue elbow outlet and remove the other two.
Tilt the flange and withdraw the elbow.
The boiler is supplied with the left hand flue outlet sealing
plate removed. If another flue outlet direction is required,
remove the appropriate flue outlet sealing plate and transfer
it to the left hand position.

Supplied By www.heating spares.co Tel. [phone]
INSTALLATION INSTRUCTIONS - Page 14
LIFTING THE BOILER
Lift the boiler onto its mounting bracket.
FIG. 15 FIG. 16 TRANSPORTATION FOOT
Locate the studs on the air duct flange through the boiler
casing and secure using four wing nuts (accessory pack F). Position boiler on its mounting bracket so that the sides of the boiler line up with the reference lines ‘C’ on the rear wall.
Undo the two screws securing the transportation foot and
discard foot. Vertical alignment with rear wall can be
corrected using the adjustment screws at the rear of the
boiler. See FIGS. 16 & 17.
FIG. 17 SECURING BOILER
FIG. 18 FLUE ELBOW EXTENSION
Rotate the left hand adjustment screw to align one of the
holes in the base plate with hole ‘D’ in the wall. Working
through the hole in the leg, secure the base plate to the wall
using the screw from accessory pack D. Make good the wall
surface around the flue terminal. Fit optional terminal wall
plate if required.
When side fluing, slide the elbow extension onto the elbow
and ensure that it is pushed on fully. Engage the screw from
accessory pack ‘C’ into the pre-drilled hole in the elbow
extension and screw fully home. The screw which is self
drilling will pierce the elbow and secure the extension to the
elbow.

Supplied By www.heating spares.co Tel. [phone]
INSTALLATION INSTRUCTIONS - Page 15
FIG. 19 LOCATION OF PRESSURE
SENSING TUBES
Slide the flue elbow into the flue duct and locate the flange over
the studs on the fluehood ensuring that the sealing gasket is in
place. Secure the elbow to fluehood using the four brass
securing nuts. Reconnect flexible tubes to elbow. ENSURE
THEY ARE NOT KINKED. NOTE: Red tube connects the front
aluminium tube in upper chamber to the lower connection on
elbow, each being identified with a red ring.
FIG 20. PIPE CONNECTIONS
Connect system pipework to the boiler, compression fittings
should be used. If however capillary fittings are used it is
essential to temporarily remove the thermostat bulb from the
flow pipe before soldering. A drain off tap should be installed
close to the boiler if it is in a low point of the system.
On combined gravity hot water/pumped central heating
installations the flow and return pipes for both the gravity hot
water circuit and pumped central heating circuit must be
connected to tees fitted directly to the flow and return pipes on
the boiler.
The gravity circuit should be installed in 28mm copper pipe.
28mm tees should be used on 50e, 60e & 80e boilers and
22mm tees on 30e & 40e boilers expanding to 28mm on the
gravity circuit as close to the tee as possible.
The injector disc (accessory pack H) must be positioned in the
pumped return branch of the tee and the pipes connected to the
tees as illustrated in Figs. 20, 20A and 20B. Two discs are
provided, one to suit a 22mm tee and one to suit a 28mm tee.
Use the appropriate disc and discard the other.
Connect the gas supply pipe to the inlet of the gas cock. Ensure
that the gas cock is in a position where it can be easily operated
when the controls cover is removed.
FIG. 20A PROFILE 30e and 40e FIG. 20B PROFILE 50e, 60e and 80e.
WARNING: UNDER NO CIRCUMSTANCES SHOULD A ‘REDUCING SET’ BE FITTED

Supplied By www.heating spares.co Tel. [phone]
INSTALLATION INSTRUCTIONS - Page 16
FIG. 21 OVERHEAT THERMOSTAT BULB
POSITION
ELECTRICAL
The boiler and all external control circuit wiring must be
supplied from the same single isolating switch or plug and
socket, and should be fused at 3A.
Care must be taken to ensure that all wiring to the boiler is
kept clear of sharp edges and hot surfaces.
Ensure that the system change-over switch in the control
box is correctly set e.g. for GRAVITY DHW system or
FULLY PUMPED system. See FIG. 2.
If the boiler is to be used on a GRAVITY DHW system the
bulb of the overheat thermostat must be repositioned as
shown in FIG. 21. To do this loosen the plastic retaining
screw and withdraw the thermostat bulb from its pocket.
Position the bulb as illustrated and secure it by finger
tightening the plastic screw. Do not over-tighten.
FIG. 22 PRINCIPLE OF WIRING
FIG. 23 ACCESS TO THE BOILER ELECTRICAL
TERMINAL BLOCK
The boiler terminal block which is situated in the control box
is not designed to accept wiring from all the on site controls
and therefore the installer will usually need to incorporate a
suitable junction box. This may not be required if a Potterton
Electronic Programmer is used as this incorporates a
junction box. The principle of wiring is shown in FIG. 22.
Further information on wiring of system controls can be
found in the Control System, Pipework and Wiring Guide.
Remove control box securing screw and lower the control
box to gain access to the boiler terminal block.

Supplied By www.heating spares.co Tel. [phone]
INSTALLATION INSTRUCTIONS - Page 17
FIG. 24 ROUTING OF ELECTRICAL WIRING
Following the pump manufacturer’s instructions connect the
pump supply wires to terminals marked PUMP L,N, ‘ ’-on the
boiler terminal block. Route the cable through the plastic bush in
the rear of the control box as illustrated in FIG. 24 and secure,
using the cable clamp.
Route a four core cable through the plastic bush in the rear of
the control box and the cable clamp as illustrated in FIG. 24 and
connect it to the boiler input terminals as follows:—
Fully Pumped Systems.
Permanent live to terminal marked MAINS ‘L’.
Neutral to terminal marked MAINS ‘N’.
Earth to terminal marked ‘ ’adjacent to cable clamp.
See NOTE.
Switched live from external controls to terminal marked
MAINS ‘SwL’.
If there are no external controls fitted connect the SwL
terminal to permanent live in the junction box.
Gravity Domestic Hot Water/Pumped Central
Heating Systems.
Switched live from external gravity domestic hot water control
circuit to terminal marked MAINS ‘SwL’. Switched live from
external pumped central heating control circuit to terminal
marked MAINS ‘L’. Neutral to terminal marked MAINS ‘N’.
Earth to terminal marked ‘ ’adjacent to cable clamp. See
NOTE.
If there are no external controls fitted connect the SwL terminal
to permanent live in the junction box.
NOTE:
Ensure that the earth conductor is longer than the L, N & SwL
from the point of anchorage, so that the current carrying
conductors become taut before the earth conductor if cable is
pulled out of the cable clamp. When the wiring has been
completed close the control box and replace the securing screw.
FITTING SIDE INFILL PANELS
If required, the gap between the casing sides and rear wall
can be closed off using the infill panels supplied.
Ensure the casing surface is FULLY CLEAN AND DRY.
Remove the protective backing paper from the adhesive strip
on the infill panel, carefully align and press into place,
applying FIRM EVEN pressure down the FULL LENGTH of
contact area between panel and case. If conditions are near
freezing, the boiler case should be warmed prior to
application of the infill panel.
FIG. 25

Supplied By www.heating spares.co Tel. [phone]
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.
All Systems
Refit the fan assembly and reconnect the fan supply leads,
(polarity of the fan leads is not important).
The whole of the gas installation including the meter should
be Inspected and tested for soundness and purged in
accordance with the recommendations of BS6891.
Test pilot unions for gas soundness as follows:— Turn boiler
thermostat to the ‘0’ position.
Unplug the gas control valve supply lead from the control
box and plug it into the test socket adjacent to the boiler
thermostat knob, see FIG. 24.
Turn on gas at the gas service cock.
Ensure that the time control if fitted is in an ON condition,
and that the room and/or cylinder thermostats where fitted
are set to high temperatures.
Switch on the external electricity supply to the boiler.
Gas will flow to the pilot only. It will not be ignited as the
ignition system is de-energised.
Using a leak detection fluid, check pilot unions for gas
soundness.
Turn off the external electicity supply and gas service cock.
Remove gas control valve plug from the test socket and refit
the plug into the socket on the left hand side of the control
box see FIG. 24.
Refit the combustion chamber front panel.
Fit the case door into position by lifting it onto the top hinge
brackets and secure it with the lower two fixing screws.
ENSURE THAT A GOOD SEAL IS OBTAINED
Remove the temporary label from the front of the casing,
having checked compliance with the information it contains.
First Lighting
WARNING: Before lighting the boiler, ensure that the CASE
DOOR HAS BEEN CORRECTLY FITTED and that the
sealing strip fitted to the case door is forming a tight seal
with the main boiler casing. Before proceeding to light the
boiler, check that the external electricity supply to the boiler
is switched off and that the boiler thermostat is in the ‘0’
position.
Turn on the gas service cock.
Ensure that the pump and radiator isolating valves are open.
Ensure that the time control, if fitted is in an on condition,
and that the room and/or cylinder thermostats, where fitted
are set to high temperatures.
Switch on the external electricity supply to the boiler. In the
event of an electrical fault after installation of the appliance,
preliminary electrical system checks must be carried out as
described in the BG multimeter instruction book. The checks
to be carried out are:-
A. Earth Continuity
B. Short Circuit
C. Polarity
D. Resistance to Earth
Refer to Fault Finding Chart FIG. 31
Turn the boiler thermostat on and to a high setting and after
a period of time the main burner will light, this can be
observed through the sight glass in the front cover of the
boiler. The time period can vary upwards of 45 seconds,
depending on the amount of air in the pipework.
Test for gas soundness around the boiler components using
leak detection fluid.
Turn the boiler thermostat to ‘0’.
NOTE:
There could be a delay in lighting if the control knob is
switched on and off and then on again rapidly.
SETTING AND CHECKING OF CONTROLS
With the controls cover removed.
Fit a pressure gauge to the pressure test nipple in burner
supply pipe. See FIG. 2.
Turn on the boiler thermostat and ensure that the main
burner is alight. Check that the burner pressure is in
accordance with values stated under TECHNICAL DATA.
The burner pressure is set to the maximum output at the
factory.
If burner pressure adjustment is necessary proceed as
follows, referring to FIG. 26.
WHITE RODGERS GAS CONTROL VALVE
Remove the brass cover screw from the gas control valve
and turn the screw beneath, clockwise to increase the
pressure or anti-clockwise to decrease the pressure.
HONEYWELL GAS CONTROL VALVE
Turn the pressure adjustment screw anti-clockwise to
increase the pressure or clockwise to decrease the pressure.

Supplied By www.heating spares.co Tel. [phone]
COMMISSIONING - Page 19
FIG. 26 MAIN BURNER PRESSURE ADJUSTMENT
With the burner set to its correct pressure, the firing rate
given in TECHNICAL DATA should also be obtained and this
should be checked by meter reading at least 10 minutes
after the main burner has been lit. When the pressure and
rate are correct replace the brass cover screw on WHITE
RODGERS gas control valve.
Shut down the boiler remove the pressure gauge and refit
the screw in the test nipple ensuring that a tight seal is
made.
Remove the self-adhesive arrow from the inspection ticket
tied to the burner supply pipe and stick it to the Data Plate
inside the controls cover to indicate the appropriate burner
setting pressure.
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 and spark
earthing strip see FIG. 30. If the pilot flame is not as
illustrated, remove and clean the pilot as described in the
Servicing Instructions Section 3, PILOT BURNER, Page 22.
Boiler Thermostat
At its minimum and maximum settings, the thermostat
should control the water flow temperature at approximately
550C—820C (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.
Gravity Hot Water/Pump Over-Run Thermostat
The function of this thermostat is determined by the position
in which the GRAVITY/FULLY PUMPED SYSTEM selection
switch is set. The thermostat is pre-set and no adjustment is
possible.
On the FULLY PUMPED switch position it will operate as a
pump over-run thermostat and will keep the pump running
after the boiler has shut down, as long as the water
temperature within the boiler is above approximately 800C.
On the GRAVITY switch position it will operate in series with
the boiler thermostat when only the gravity domes-tic hot
water circuit is in operation.
It will over-ride the boiler thermostat when the water
temperature within the boiler is above 800 C.
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.

Supplied By www.heating spares.co Tel. [phone]
COMMISSIONING - Page 20
FIG. 27 FUNCTIONAL FLOW DIAGRAM
FIG. 28 BOILER WIRING DIAGRAM