Potterton Statesman 50/70L Installation and maintenance instructions

About the Boiler This is a Floor Standing, Horizontally Fired, Automatic Pressure Jet Oil Boiler.
The boiler can be flued conventionaly or with a kit as a balanced flue.
This boiler is for use with Kerosine and for use in GB & IE.
This boiler can be converted for use with Gas Oil (CF only, not 45/50L).
About Safety Installation must be in accordance with the Installation & Service Instructions and the rules in
force.
Leave these instructions with the user for use on future calls.
Statesman
45/50L, 50/70L,
70/90L, 90/110L
Installation & Service Instructions

2Part No. 5105707Contents
Contents
Section 1 -Technical Data...............................................4
Health & Safety Information..........................................4
Control Panel Wiring Diagram......................................5
Technical Data..............................................................6
Boiler Dimensions & Clearances..................................7
Flue Layouts.................................................................8
Section 2 - Pre-Installation Requirements....................9
Chimneys/Flues.........................................................10
Combustion &Ventilation Air Requirements...............11
Balanced & Low LevelTerminal Clearances...............12
Oil Tanks & Layouts....................................................14
Floor Temperatures....................................................16
Section 3 - Installation & Commissioning..................18
Conventional Flue......................................................19
Electricity Supply........................................................19
Fuel Pipes..................................................................20
Wiring Diagrams.........................................................21
Water Connections.....................................................22
Thermostats...........................................................22
Commissioning.......................................................24
Section 4 - Servicing & Maintenance...........................27
Servicing................................................................27
Maintenance...........................................................27
Replacement of Parts.................................................28
Limit Thermostat........................................................29
Boiler Control Thermostat..........................................29
Section 5 - Fault Finding..............................................30
Burner does not start, motor does not run..................30
Burner starts, no flame established, no
oil to burner.................................................................30
Burner starts, no flame but oil to burner......................31
Burner starts, flame established but goes to
lockout after 15 seconds.............................................31
Locks out in mornings only.........................................31
Flame established but not maintained........................32
Burner runs but smoke, and or smell,
and or pulsation..........................................................32
Other problems..........................................................33
Section 6 - Spare Parts.................................................34
Section 7 - Flue Kit Options..........................................35

Part No. 5105707 3Safety
WARNING ! - this is about YOUR safety
Safe use of Kerosines and Gas Oils
Hazards
These fuels give off a flammable vapour when heated even moderately.
This vapour ignites easily, burns fiercely and can be explosive.
Vapour can flow along at ground level and collect as an explosive mixture in drains, cellars etc. at considerable
distances from open containers or spillages.
Fuels remove natural oils and fats, and may thus cause cracking and irritation of the skin.
Gas oil may also cause irreversible damage to your health on prolonged or repeated skin contact.
Precautions
ALWAYS HANDLE fuels in the open air or in a well ventilated place, well away from all sources of ignition
such as fires, sparks, hot surfaces and DO NOT SMOKE.
ALWAYS DRAIN fuels using a proper fuel retriever, mechanical siphon or funnel.
NEVER SUCK fuels up a tube by mouth. If accidentally swallowed - call a doctor - DO NOT INDUCE
VOMITING.
NEVER APPLY heat to a fuel tank, pipework or container.
AVOID INHALING fuel vapour; it can make you light-headed and seriously impair your judgement.
ALWAYS STORE fuels in a properly constructed and labelled tank.
If there is a Fuel Spillage
IMMEDIATELY STOP/SWITCH OFF all electrical and other ignition risks
REMOVE all contaminated clothing to safeguard yourself against fire risk and skin damage.
Wash the affected skin thoroughly with soap and water and remove the clothing to a safe, well
ventilated place and allow to air before washing or dry cleaning.
CONTAIN and smother the spill using sand, soil or other suitable incombustible material.
DO NOT ALLOW spilled fuel to escape into drains or water courses. If fuel does enter a drain, warn the Water
Authority and Fire Brigade.
CONSULT your Local Authority about disposal of contaminated soil.
FIRST AID if fuel is accidentally swallowed, SEEK IMMEDIATE MEDICAL ATTENTION - DO NOT INDUCE
VOMITING.
if fuel is splashed into eyes, wash out with running water for at least 10 minutes and SEEK
IMMEDIATE MEDICAL ATTENTION.

4Part No. 5105707Technical Data
1 - Technical Data
• The Statesman boilers are horizontally fired,
automatic pressure jet boilers. These boilers are
intended for use on indirect central heating systems.
Their use on direct systems is not recommended.
• The boilers as supplied can be installed directly to
suitable conventional chimneys. For balanced flue
installations, an appropriate flue kit is additionally
required.
• The Statesman boilers have been independently
tested to standards EN 55014 and EN 50082-1 and
show compliance with the E.M.C. Directive 89/336/
EEC.
• The boiler has an easily removable front access door
which gives quick access for cleaning.
• The maximum static head of water permissible is
27.44 metres (90 ft).
• Water flow and return connections are provided on
each side and rear of the boiler (dependant on model).
Note: When installing the boiler, make sure all
unwanted tappings are blanked off.
Health & Safety Information for the Installer &
Service Engineer
Under the Consumer Protection Act 1987 and Section
6 of the Health and Safety at Work Act 1974, we are
required to provide information on substances
hazardous to health.
Small quantities of adhesives and sealants used in
the product are cured and present no known hazards
when used in the manner for which they are intended.
The following substances are also present:
Insulation and Seals
Material - Man Made Mineral Fibre.
Description - Boards, Ropes, Gaskets.
Known Hazards - Some people can suffer reddening
and itching of the skin. Fibre entry into the eye will
cause foreign body irritation which can cause severe
irritation to people wearing contact lenses. Irritation
to respiratory tract.
Precautions - Dust goggles will protect eyes. People
with a history of skin complaints may be particularly
susceptible to irritation. High dust levels are only likely
to arise following harsh abrasion. In general, normal
handling and use will not present high risk, follow
good hygiene practices, wash hands before, touching
eyes, consuming food, drinking or using the toilet.
First Aid - Medical attention must be sought following
eye contact or prolonged reddening of the skin.
Flue Gas Sampling Point
To aid commissioning, a flue gas sampling point is
built into the heat exchanger front access door. If
this door is removed make sure that when re-fitted,
the sampling point is at the top.
Oil Pipe Installation
The boiler base features "Knock Out" holes for
installation purposes. Remove using a drift or dot
punch as required. Grommets are provided for cable
protection within the connection pack. Additional
holes have been provided in the front of each side of
the base.These are to provide more options when
bringing in the fuel hoses and if required, electrical
wiring.
Burner
The burner is an automatic pressure jet type, pre-wired,
with a photocell flame failure control.
The standard burner fitted is the Riello RDB range with
different combustion heads to suit boiler ratings.
BoilerThermostats
A pre-wired control thermostat is provided with each
boiler.This thermostat is calibrated to give a maximum
boiler temperature of 82°C (180 °F) and a minimum
temperature of 55 °C (130 °F).Under no circumstances
should the boiler be operated below the minimum
indicated setting, or below a flow temperature of 55
°C (130 °F). For best operation it is suggested that
the boiler should be operated at a setting just below
maximum on the thermostat setting. The boiler also
has a limit (overheat) thermostat calibrated to operate
at 110 °C (230 °F). This is located on the underside
of the control panel, see the Users Instructions.
System & Boiler Control
Due to the high efficiency of the Statesman boilers,
the following should be taken into consideration during
installation:-
Control of the Boiler: When the demand for heating
and/or hot water is satisfied, the controls should be
arranged such that the burner is switched off. If due
to the system design nuisance tripping of the overheat
thermostat occurs, it may be advisable to fit a pump
overrun device (Incorporating a by-pass system where
necessary).

Part No. 5105707 5Technical Data
Fig. 1
Side Flue
Knockout
Top Flue
Knockout
Flue Outlet
Flange
Thermostat
Pocket
Flow Outlet
Return Inlet
Knock-out
Holes For
Cables And
Fuel Pipes
Side
Cover
Burner
Air Inlet
Boiler Shell
Burner Oil
Feed Pipe
Statesman
Top Casing
Side Flue
Knockout
Thermostat
Pocket
Front Access
Door
Burner Lead
Flue Gas
Sampling
Viewing Window
Front Cover
Burner
Lockout Reset
Button
Control
Thermostat
Indicator Lights
Programmer
(Optional)
ST00205A
Fig. 2
ST00123C
N
L
N
L
N
L
N
N
E
E
L
L
N
N
L
N
L
N
L
Terminal
Block
Terminal
Block
Overheat
Burner
Lockout
Mains
On
NEL
Burner
Socket
Main Socket
Chassis Earth
Boiler
Terminal
Socket
(6 way)
Boiler
Terminal
Plug
(6 way)
Limit
Stat.
Boiler
Stat.
L2
L1
E
N
1
1
2
2
Main
Supply
Connection
Colour Coding
For The Wiring
b - Blue
br - Brown
gy - Grey
r - Red
bl - Black
g/y - Green/Yellow
bg/y
g/y
br
br
br
r
b
b
g/y
bl
br
b
g/y
gy
gy
br
br br
r
bl
bl
b
br
b
br
b
b
b
br
Boiler Control Panel
Wiring Diagram
Statesman
NEL
Live
Main
Supply
Connection
LL
E
E
NN
S/L S/L
Neutral
Earth