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

6Part No. 5105707Technical Data
Technical Data
Model 45/50 50/70 70/90 90/110
Btu/h kW Btu/h kW Btu/h kW Btu/h kW
Maximum Output 51,000 15 68,000 20 89,000 26 110,000 32
Minimum Output 44,000 13 51,000 15 68,000 20 89,000 26
Factor
y
Set Output Kerosine 51,000 15 60,000 17.5 79,000 23 99,000 29
Riello Burner T
y
pe RDB1 RDB1 RDB1 RDB2
Combustion Head T
y
pe Kerosine LD2SH LD2SH LD3 LD3
Gas Oil LD2SH LD2SH LD3 LD3
Nett Full Load Efficienc
y
% 93.2 91.9 91.0
Boiler Gas Volume m³ 0.041 0.041 0.058
Exit Flue Gas Mass Flow (Max) K
g
/h 23.42 32.45 40.09
Flue Gas Temperature Rise Above Ambient ºC 200 190 205
Resistance To Combustion Products mbar 0.15 0.3 0.4
Maximum Hearth Temperature ºC 60 50 50
Water Side Resistance (Cold)
10ºC Differential mbar 11.0 11.0 21.2
20ºC Differential mbar 4.0 4.0 6.7
Maximum Static Head
Minimum Static Head
Maximum Operatin
g
Temperature
Minimum Operatin
g
Temperature
Maximum Boiler Operatin
g
Pressure
Conventional Flue Drau
g
ht at Boiler Flue Outlet
Limit Thermostat Settin
g
Maximum Casin
g
Panel Temperature
Maximum Surface Temperatures of
Adjustin
g
, Control & Safet
y
Devices
Electrical Suppl
y
Table 1
Less Than 35ºC Above Room Temperature
Less Than 30ºC Above Room Temperature
230V 1 Phase 50Hz Fuse 5A
55ºC (131ºF)
3 Bar (43.5 p.s.i.) (Class 2)
0.035"w.
g
. (8.75N/m²) Minimum 0.16"w.
g
. (40.0N/m²) Maximum
110ºC (230ºF) Manual Reset
1.9
90ft. Water (40 p.s.i.)
5.0ft. Water (3.0 p.s.i.)
82ºC (180ºF)
195
0.45
50
18.3
90.8
0.055
51.62

Part No. 5105707 7Technical Data
SEDBUK Declaration for Statesman
(Kerosine)
Model Seasonal Efficiency
(SEDBUK) (%)
45/50 85.7
50/70 85.7
70/90 85.3
90/110 85.2
This value is used in the UK Government's
Standard Assessment Procedure (SAP) for
energy rating of dwellings. The test data
from which it has been calculated have
been certified by 1053.
Boiler Dimension & Clearances
SEDBUK Declaration for Statesman
(Gas Oil - Mid Range)
Model Seasonal Efficiency
(SEDBUK) (%)
50/70 85.5
70/90 85.5
90/110 85.4
This value is used in the UK Government's
Standard Assessment Procedure (SAP) for
energy rating of dwellings. The test data
from which it has been calculated have
been certified by 1053.
Model 45/50 50/70 70/90 90/110
Hei
g
ht mm A 850 850
Width mm B 390 390 490 490
Depth mm C 565 565
Centre of Flue from rear mm D 100 100
Flue Diameter mm E 100 100
Hei
g
ht between connections mm F 569 569
Hei
g
ht of bottom connection mm G 97 97
Distance of connection from wall mm H 59 59
Return Connections 2 off J 1" B.S.P. 1" B.S.P. 1" B.S.P. 1" B.S.P.
Flow Connections 2 off K 1" B.S.P. 1" B.S.P. 1" B.S.P. 1" B.S.P.
Wei
g
ht Empty K
g
105 128
Water Content Litre 18.2 22.5
Water Content Imp 4.0 5.0
Oil Supply Connection BSP ¼" ¼" ¼" ¼"
Installation Clearances
Front mm 610 610 610 610
Top mm12121212
Sides (Balanced Flue) mm 6 6 6 6
Sides (Conventional Flue) mm 25 25 25 25
Table 2
4.0 4.5
105 122
18.2 20.5
97 97
59 59
125 125
569 569
565 565
100 100
850 850

8Part No. 5105707
ST00269A
610mm
Min.
Minimum
Boiler
Clearances
Flue Options:
12mm
Min.
6mm
or
25mm
Min.
Low Level Horizontal High Level Horizontal High Level Vertical
For Flue Lengths see tableFor Flue Lengths see tablesFor Flue Lengths see tables
1.6m Min.
2.1m Max.
Floor
Level
Floor
Level
Intersection
With Roof
Kit 3
Kit 4
Kits 9 or 10
770mm
Floor Level
Kits 1 & 2
Kits 7 & 8
Kits 5 & 6
(if required)
Kits 5 & 6
(if required)
Kits 5 & 6
(if required)
Kit 3 2.150m Min.
4.550m Max.
20mm
Flue
Outlet
Flue
Outlet
Flue
Outlet
C
D
D
K
F
A
Flue
Outlet
B
Boiler
Dimensions
D
Knock-out Blanks
For Cables
And Fuel Pipes
GJ
H
6mm or
25mm
Min.
D
Low Level Riser
Flue Kits 12, 5, 6, 7, & 8
For Flue Lengths see tables
990mm
Floor
Level
Kits 7 & 8
Kit 12
Kits 5 & 6
(if required)
Flue Kits 1, 2, 5, & 6
Suitable for all Models Flue Kits 3, 5, 6, 7, & 8 Suitable for all Models Flue Kits 3, 4, 5, 6, 9 & 10 Suitable for all Models
Fig. 3
Technical Data

Part No. 5105707 9
As with all building services, the oil fired
systems have to be installed so as to ensure
safe and efficient operation. The following notes
provide a guide to current best practice. It is
important that documents relating to Building
Regulations and Standards are studied.
In addition we also recommend the following
OFTEC publications:-
Technical Information Book 3
Installation requirements for oil
fired boilers and oil storage tanks.
Technical Information Book 4
Domestic heating systems
These books are available from OFTEC, Century
House, 100 High Street, Banstead, Surrey SM7
2NN.
Training
Potterton have several training centres around the
country, for details of courses for oil firing telephone
0845 6007402. OFTEC also hold training courses
on oil fired central heating.
Regulations and Standards
The installation of oil fired boilers is covered by the
requirements of the Building Regulations which are
statutory instruments and must be complied with.
Those for England and Wales are made by the
Department of the Environment in London.
The Building Standards (Scotland) Regulations are
made by the Scottish Office. Part F of the Technical
Standards to the Regulations covers heat producing
appliances and fuel storage.
The Building Regulations (Northern Ireland) are
made by the Northern Ireland Department of the
Environment.Heat producing appliances, including
oil heating appliances, are covered by Technical
Booklet L.
The Isle of Man has its own Building Bye-laws. In
the Channel Islands, Jersey and Guernsey have
their own separate Building Bye-laws.
The British Standard covering oil fired boiler
installation is BS5410.This is issued as Part 1:1977
for installations up to 45 kW and Part 2:1978 for
larger installations. This standard also covers oil
storage tank installations.
Additional standards and regulations
• BS 5449: 1990 Forced circulation hot water Fig. 4
Pre-Installation Requirements
2 - Pre-Installation Requirements

10 Part No. 5105707Pre-Installation Requirements
Fig. 5
central heating systems for domestic
premises.
• BS 7074: Pt.1:1989 Application, selection
and installation of expansion vessels and
ancillary equipment for sealed systems.
• BS 7671 Requirements for electrical
installations. IEE wiring regulations 16th
edition.
• Control of pollution (oil) regulations.
• Local water undertakings bye-laws.
Chimney
Every Potterton boiler has a very high
efficiency and care must be taken to ensure
that the chimney is suitable.
Chimneys may have been already built and
completed before a choice of appliance has
been made. Alternatively, chimneys may
be installed to suit the particular appliance
chosen.
A factory made insulated chimney
complying with the requirement of BS4543
may be considered as an alternative to a
conventional structural chimney for both
new and existing buildings. A further
alternative may be a suitable form of
insulated flue pipe normally positioned on
a wall outside a building.
Capacity
The chimney or flue must have a cross-
sectional area throughout its whole length,
that is at least the area of the flue outlet of
the boiler and must be sealed at the boiler
with fire clay or other suitable compounds.
As few bends as possible should be used
and, where necessary, 135° bends are
recommended.
Height
The chimney or flue should be of sufficient
height to provide a minimum draught of
0.035" w.g. measured above the boiler.
Draught conditions that are excessive i.e.
above 0.16" w.g. due to chimney height or
location, should be controlled by means of
a draught stabiliser fitted to the chimney.
External Flues
All external flues of metal or other materials
should have cleaning facilities, and be well
insulated to maintain the correct draught
conditions.

Part No. 5105707 11
Fig. 6
Internal Flues
The exposed flue pipe between the boiler flue off-take
and the chimney proper (either internally or externally)
must not be of asbestos. Vitreous Cast Iron, Steel or
similar materials should be used.
Note: When installing the boiler into a chimney
previously fitted with a liner, the liner must be replaced
and made weather-tight.
Choice of Materials
The materials used in the construction of chimneys
and flues must always be suitable for the application.
Their construction must be durable, non-combustible,
able to resist the range of temperatures expected; and
also resistant to external as well as internal corrosion.
This is particularly important due to the Statesman's
high thermal efficiency, where correct choice of
materials will prevent problems likely to be caused by
condensation.
If you are in any doubt, you should seek advice of a
reputable manufacturer of chimneys, names should
be available from your local stockist.
Combustion &Ventilation Air for Open Flue Oil Fired
Boilers
General. A sufficient permanent air supply to an
appliance will be required.
a) For proper combustion of fuel and effective
discharge of combustion products to the open air.
b) For the ventilation of any confined space in which
an appliance is installed to prevent overheating of
the appliance and any equipment in and near the
appliance.
c) For the satisfactory operation of any draught break
or stabilizer which may be fitted.
Air for Combustion
This requirement will be satisfied if the room or space
in which the appliance is installed has an opening or
duct which is designed to allow the passage of air at
all times equivalent, in total free area, to 550 mm2/kW
(2.5 in2per 10,000 btu’s) of the appliance rating.
If the space containing the appliance has an extract
ventilation fan fitted, the supply of air should be such
that the operation of the appliance and flue is
unaffected when the windows and doors are closed
and the extractor fan is running.
Air for Ventilation
For an appliance in a confined space, care shall be
taken to provide air for ventilation. A working guide to
the minimum free area of openings to be provided in
addition to that for combustion air is as follows:
a) Where the air is taken from a heated space, 1100
mm2/kW at high level and 1100 mm2/kW (5.0 ins2
per 10,000 Btu’s) at low level.
b) Where the air is taken from outside, 550 mm2/kW
at both high level and low level (2.5 in2per 10,000
btu’s) at low level.
The above requirements are essential, in particular
for appliances which are installed with a low level
discharge.The warranty for such boilers could be
affected if proper free air requirements are not
provided.
FREE AREAS OF GRILLES ARE MM2PER KW
OF APPLIANCE RATING (OUTPUT)
Pre-Installation Requirements

12 Part No. 5105707Pre-Installation Requirements
Combustion & Ventilation Air for Balanced Flue Oil Fired Boilers
FREE AREAS OF GRILLES ARE mm2PER/KW OF APPLIANCE RATING (OUTPUT)
Balanced Flue
Boilers fitted with balanced flues must only fire Kerosine and will not operate satisfactorily unless the free air requirements
have been satisfied.
Consideration should be given to the texture of the wall onto which the low level flue terminal is fixed. As with all heat
emitting devices the warm air from the terminal will encourage the accumulation of dirt which will at some time require
removal with a detergent based cleaning fluid.
Clearances are shown on the next page.
Fig. 7
Extract Fans
If the room in which the appliance is located also has an
extract fan the performance of the appliance must be
unaffected when the fan is running with all doors and
windows closed.
Draught Breaks
When an appliance with a draught break is fitted in a room
add 550mm2/kW to the free area of the combustion air
inlet.
When an appliance with a draught break in a compartment
which is ventilated as noted above, no additional allowance
is required.

Part No. 5105707 13
Where the terminal is within 1 metre of any
plastic material, such material should be
protected from the effects of combustion
products.
There are additional general requirements
in most Regulations and Standards that the
flue must be positioned so that it does not
cause a nuisance and permits the dispersal
of combustion products.
If the terminal is less than 2 metres above
ground level, balcony or place to which any
person has access, the terminal must be
protected by a guard, (Flue Guard Part No.
26000045).
Table 3
Fig. 8
600
600
75
600
300
300
300
600
1200
1500
750
300
1000
Terminal Position with Minimum Distance (mm)
L
G
G
E
D
K
G
AAD
F
H,J
C
F
Likely flue positions requiring
a flue terminal guard
B
NN
M
N
M
FLU0003A
Property
Boundary
Line
Terminal
Assembly
300 min
Top
View
Pressure Jet
Appliance
FLU0004A
ADirectly below an opening, air brick, opening window
etc
BHorizontally to an opening, air brick, opening window
etc
CBelow a plastic/painted gutter, drainage pipe or eaves,
with protection
DBelow a balcony or a plastic/painted gutter, drainage
pipe or eaves
EFrom vertical sanitary pipework
FFrom an internal or external corner
GAbove ground or balcony level
HFrom a surface facing a terminal
JFrom a terminal facing the terminal
KVertically from a terminal on the same wall
LHorizontally from a terminal on the same wall
MFrom the intersection with the roof to the air intake on
the terminal
NFrom the terminal to a wall or chimney
Note: The distance from a appliance terminal installed parallel to a
boundary may not be less than 300 mm in accordance with the diagram
below.
Clearances Required Around Balanced and Low Level Discharge Flues Fitted to Oil Fired Boilers
Pre-Installation Requirements

14 Part No. 5105707Pre-Installation Requirements
Tank Support
Steel tanks are normally supported on masonry piers.
These have to maintain the tank at a sufficient height to
enable access to be gained for painting.
Requirements for Tank Accommodation
Reference should be made to the relevant building
regulations, bye-laws, etc.in order to achieve a satisfactory
degree of safety in relation to the methods of protection.
Underground tanks are also referred to in BS 5410:Pt.1.
BS 5410:Pt.2 gives more detailed guidance on the burying
of steel tanks.
The Scottish Building Standard requirements for
underground tanks are the same as those of BS 5410:Pt.1.
Methods of Tank Protection
It is considered unlikely that a fire will originate from the
stored oil and it is the purpose of these recommendations
to ensure that a fire which may originate from a building
or other external source is not transmitted to the tank
contents.
Adequate safety may be achieved in a number of ways,
for example:
a) Protecting the tank by a physical barrier or isolating
the tank by sufficient space;
b) Enclosing the tank by non-combustible fire resisting
construction; i.e., putting the tank underground.
Oil Storage Tank & Supply Installations
Oil Tank Types
SteelTanks
Steel tanks should be constructed so as to comply
with BS 799:Pt.5:1987. Galvanised steel pipework or
valves must never be used for oil storage or supply
systems.
PlasticTanks
Tanks made from plastics material are now available.
Oil should never be stored in translucent plastic
containers.
Fig. 9

Part No. 5105707 15
Storage Requirements andTank Sizes
Tanks are available in a wide variety of sizes and
capacities. For boilers of up to 13 kW (45,000 Btu/h)
tanks with a capacity of 1200 litres (250 gallons) are
satisfactory. Above that size of boiler a larger capacity
tank should be considered.
Some typical tank sizes and capacities are noted below
Length Width Height Capacity
Metres Metres Metres Litres
SteelTanks
1.52 1.22 0.61 1130
1.83 0.61 1.22 1360
1.83 1.22 1.22 2700
2.44 1.22 1.22 3650
Polythene Tanks
2.03 0.69 1.36 1150
1.37 1.06 1.25 1250
2.02 1.36 1.36 2500
Tank Fittings
TANKS REQUIRE TO BE PROVIDED WITH THE
FOLLOWING FITTINGS:
Fill Pipe
A 50 mm diameter black steel fill pipe terminating with
a 50 mm male BSP thread hose coupling connection
and non ferrous screw cap and chain.
Extended Fill Pipe
Extended fill pipes can be used when the location of
the tank is such that access for filling would be difficult
for a delivery tanker carrying 30 metres of hose.
Extended fill lines must be run in 50 mm diameter black
steel tube with proper support. They must be arranged
so as to be self draining, preferably in to the tank.
Where tanks are located lower than their filling
connection care must be taken to ensure that the
pressure head of oil applied during filling is not
excessive.
Where the use of an extended fill pipe means that the
delivery driver cannot see the oil tank, an audible alarm
should be fitted to indicate that the tank is nearly full.
Vent Pipe
A separate vent pipe with an internal diameter at least
equal to that of the fill pipe must be fitted. The open
end of the vent is fitted with a return bend and an open
wire mesh balloon.
A mushroom type vent may be fitted provided its free
area is at least equal to the cross sectional area of the
fill pipe. The vent should normally rise no higher than
600 mm above the top of the tank.
If the vent pipe rises more than 600 mm above the
tank a pressure relief outlet must be provided in the
vent at the 600 mm level. This is normally a horizontal
branch off the vent with a flap at its end. This is hinged
at the top and fitted so that it is normally closed but
will open easily if oil rises up to the level of the branch.
Isolating Valve
A valve is fitted in the tank outlet in an accessible
position so that the oil supply to the burner can be
shut off if required.
The valve must be of a type suitable for use with oil.
The outlet from the tank must be above the level of the
bottom of the tank to prevent water and sediment being
drawn in to the oil supply pipe.
Drain Valve
In order to enable the sediment and water to be
removed from the tank a gate valve and plug are fitted
in the bottom plate of the tank.
Contents Gauge
The most commonly used gauge is the sight tube type.
These are simple and have some advantages for
domestic use. An isolating valve must always be
provided and is often incorporated in the gauge
connection.The top of the gauge must be fixed to the
top of the tank and provided with a cap to protect the
oil from foreign matter. Integral gauges using internal
floats are also available.These are less likely than sight
gauges to give rise to leaks.
Overfill Alarms
Audible alarms can be fitted in tanks to indicate that
they are nearly full.These are an essential requirement
when the delivery point and tanker access are remote
from each other.
Oil Supply Pipe Layout
Oil can be run from the storage tank to the burner by a
single pipe gravity flow if there is a sufficient height
difference between the bottom of the tank and the
burner. Otherwise a two pipe system is needed.
a) Single Pipe Supply Systems - Tanks serving
Pre-Installation Requirements

16 Part No. 5105707
appliances with pressure jet burners by means of
a single pipe need to be positioned so that they will
apply the 300 mm minimum required head of oil to
the burner when the fuel level is at its lowest point.
The fittings and layout are shown in Fig. 10.
b) Two Pipe Supply Systems - If the tank base is
below the level at which gravity feed to the burner
can be maintained, a two pipe oil supply system
can be adopted. The fittings and layout are shown
in Fig. 11.The non return valve in the supply line of
the two pipe system is required to prevent oil
running back from the burner and un-priming the
oil pump. The non return valve in the return line is
only required if the top of the tank is above the
burner. Its purpose is to prevent oil running back
through the burner during maintenance.
Oil Line De-Aerating Devices
These may be used in conjunction with Statesman
boilers. It is recommended that they are fitted outside
the dwelling. It is not permissible to fit plastic
components in fuel lines within dwellings or boiler
rooms.The manufacturers instructions should always
be followed, particularly when the oil tank may be
situated at low level.The fittings and layout are shown
in Fig. 10.
Oil Filter
An oil filter should always be fitted in the oil supply
line. Facilities should be provided to enable it to be
serviced without draining down the oil supply system.
FireValves
A fire valve is an essential part of the oil supply system.
It should be capable of cutting off the flow of oil outside
Pre-Installation Requirements
Pipe Dia
I/D in mm. 8 10
'A' Metres Length in Metres
0.5 10 20
1.0 20 40
1.5 40 80
2.0 60 100
Table 4
Figures for
Kerosine Only
Pipe Dia
I/D in mm. 8 10
'B' Metres Length in Metres
0.0 100 100
0.5 100 100
1.0 100 100
1.5 100 100
2.0 100 100
2.5 80 100
3.0 55 100
3.5 5 90
Table 5
Figures for
Kerosine Only
the building in the event of a fire starting up within the
boiler.
The valve should be located just outside the building
at the point where the oil supply line enters. It must be
activated by a remote sensor located over the burner
but in a position clear of any direct radiation or
excessive heat.Weight operated valves connected to
a sensor by wires and pulleys have been used for this
purpose. It is preferable, however, to use a valve with
a capillary connection between its sensor and the oil
cut off mechanism. The use of fusible head isolating
valves is not recommended.
It is essential that these devices conform to current
Standards and Regulations.When they are
installed, their manufacturers recommendations
must be adhered to.
Copper Tube and Fittings
Copper tube for oil lines should be to BS.2871:Part 1:
TableY. It can be obtained in coil form or half hard for
use with bending machines.This pipe can be obtained
with protective plastic sheathing applied. Copper tubes
for oil lines must not be soldered.
Note: Galvanised pipes must not be used.
Fittings for copper pipe should be of the flared
manipulative type to BS.864:Part 2:1983. Steel pipe
should be to BS.1387:1985. Fittings for steel pipe
should be to BS.1740:Part 1:197271 with taper threads.
FloorTemperatures
The thermal insulation provided in the boiler base
ensures the floor temperatures is kept below 80 °C
and as such, a non combustible hearth is not required.
The floor should always be smooth and flat and capable
of supporting the installed weight of the boiler, including
its water content.If constructed by a material which is
softened by oil, it is advisable to install an additional
metal tray underneath the boiler for protection against
accidental damage.
The Heating System
When fitting into an existing installation, the system
should be chemically cleaned (if practical) before
installing the boiler. A suitable inhibitor should be added
to keep it in good condition.

Part No. 5105707 17
Oil Tank
Below Burner
Fire Valve
Non-Return
Valve
Non-Return Valve
Shut Off
Valve
Oil Return Pipe
Oil Supply
Pipe
Filter
Fire Valve
Sensor
ST00203A
150mm
Pump
Twin Pipe Supply System
'B'
Max. Oil Level 4 metres
Above Burner
Fire Valve
Shut Off
Valve
Filter
Fire Valve
Sensor
Pump 'A'
Single Pipe Supply System
Max.
Head 4m
Oil Tank Below
or Level
with Burner
Fire Valve
De Aeration
Device
Isolating
Valve
Isolating
Valve
Oil Supply
Pipe
Filter
Fire Valve
Sensor
Pump
Fig. 11
Fig. 10
Pre-Installation Requirements

18 Part No. 5105707Installation & Commissioning
ST00270A
High Level Vertical - Kits 3, 4, 9 & 10 With Extensions
Casing
Kit 3
Kits 5 or 6
Kit 10
Kit 4
Kit 4
Floor Level
300 Min.
950
950
*Two
Kit 5
Max.
Wall
103mm
Roof
Pitched
1000mm to wall,
or chimney
1000mm
to wall
or chimney
Kit 5
950
Kit 6
300
All Dimensions in mm
Kit 4
Kit 4
Kit 9
Flashing
Flat Roof
Flat Roof
Flashing
Pitched Roof
300
Min.
Roof
Height
Roof
Height
High Level Vertical
ALL Models
Kit
Numbers
2,150
2,450
3,400
3,100
2,750
3,700
4,050
2,650
2,950
3,900
3,600
3,250
4,200
4,550
3 + 4
3 + 4 + 6
3 + 4 + 5
3 + 4 + 6 + 6
3 + 4 + 5 + 6 + 6
3 + 4 + 5 + 5
3 + 4 + 5 + 6
Min. Max.
All Dimensions in
Tables ± 5mm
Fit Dress Plate
to the Ceiling
(if required)
175 Min.
225 Max.
Kit 3
Floor Level
All
Dimensions
in mm
Kits 7 & 8
(Terminal)
Kits 7 & 8
(Elbow)
Wall
Width
High Level Horizontal - Kits 3, 7 & 8 With Extensions
1600 Min.
2100 Max.
12
103
Kit 5
Kit 5
950mm
300mm
Kit 6
Kit 6
Wall
Width Wall Width Wall Width
High Level Rear
ALL Models
High Level Left/Right
45/50 50/70 Models
High Level Left/Right
70/90, 90/110
Kit
Numbers Kit Numbers Kit Numbers
100 - 275 100 - 175 100 - 125
225 - 525 125 - 425 100 - 375
525 - 825 425 - 725 375 - 675
825 - 1,125
1,125 - 1,225
1,225 - 1,475
725 - 1,025
1,125 - 1,375
1,025 - 1,125
675 - 975
975 - 1,075
1,075 - 1,325
3 + 7 3 + 7 3 + 7
3 + 8 3 + 8 3 + 8
3 + 8 + 6 + 6 3 + 8 + 6 + 6
3 + 8 + 5 3 + 8 + 5
3 + 7 + 5 3 + 7 + 5
3 + 8 + 6 3 + 8 + 6
3 + 8 + 6
3 + 8 + 6 + 6
3 + 7 + 5
3 + 8 + 5
Casing
All Dimensions in
Tables ± 5mm
Kits 5 and/or 6
(Extension)
Dress Plate (Outer Wall)
Dress Plate (Inner Wall)
Max. Min.
The terminal can be extended
between these markers
Low Level Horizontal - Kits 1 & 2 With Extensions
126
12 Min.
770 Casing
Kits 1 & 2 (Flue)
Dress Plate
(Outer Wall)
Dress Plate
(Inner Wall)
Floor Level
All Dimensions in mm
All Dimensions in
Tables ± 5mm
Kit 5
950mm
Kit 6
300mm
Kits 1 & 2
(Terminal)
Kits 5 and/or 6
(Extensions)
Wall
Width
Wall
Width
Wall
Width
Low Level Rear
ALL Models
Low Level Left/Right
45/50 50/70 Models
Low Level Left/Right
70/90 90/110
Kit
Numbers
Kit
Numbers
Kit
Numbers
Wall Width
175 Min.
225 Max.
100 - 275 100 - 250 100 - 200
225 - 600 125 - 500 100 - 450
600 - 900
900 - 1,200
500 - 800 450 - 750
1,200 - 1,550
1,550 - 1,850
800 - 1,100
1,100 - 1,450
1,450 - 1,750
750 - 1,050
1,050 - 1,400
1,400 - 1,700
111
222
2 + 6 2 + 6 2 + 6
2 + 6 + 6 2 + 6 + 6 2 + 6 + 6
2 + 5 2 + 5 2 + 5
2 + 5 + 6 2 + 5 + 6 2 + 5 + 6
Max. Min.
The terminal can be extended
between these markers
Low Level Horizontal - Kits 7, 8 & 12 With Extensions
175 Min.
225 Max.
Kit
12
Floor Level
All
Dimensions
in mm
Kits 7 & 8
(Terminal)
Kits 7 & 8
(Elbow)
Wall
Width
990
12
103
Kit 5
Kit 5
950mm
300mm
Kit 6
Kit 6
Wall
Width
Wall
Width
Wall
Width
Low Level Rear
ALL Models
Low Level Left/Right
45/50 50/70 Models
Low Level Left/Right
70/90, 90/110
Kit
Numbers
Kit
Numbers
Kit
Numbers
100 - 275 100 - 175 100 - 125
225 - 525 125 - 425 100 - 375
525 - 825 425 - 725 375 - 675
825 - 1,125
1,125 - 1,225
1,225 - 1,475
725 - 1,025
1,125 - 1,375
1,025 - 1,125
675 - 975
975 - 1,075
1,075 - 1,325
12 + 7 12 + 7 12 + 7
12 + 8 12 + 8 12 + 8
12 + 8 + 6 + 6 12 + 8 + 6 + 6
12 + 8 + 5 12 + 8 + 5
12 + 7 + 5 12 + 7 + 5
12 + 8 + 6 12 + 8 + 6
12 + 8 + 6
12 + 8 + 6 + 6
12 + 7 + 5
12 + 8 + 5
1,475 - 1,775 12 + 8 + 5 + 6 1,375 - 1,675 12 + 8 + 5 + 6 1,325 - 1,625 12 + 8 + 5 + 6
Casing
All Dimensions in Tables ± 5mm
Kits 5 and/or 6
(Extension)
Dress Plate (Outer Wall)
Dress Plate (Inner Wall)
Max. Min.
The terminal can be extended
between these markers
Fig. 12
3 - Installation & Commissioning

Part No. 5105707 19
Installation & Commissioning
It is possible to install the boiler without removing
the casing sides but care should be taken not to
damage the panels when connecting the water
pipes.
Fitting a Balanced Flue
Refer to the Instructions supplied with the flue.
Fitting a Conventional Flue
Local Building Regulations and Bye Laws should
be consulted for details of the chimney, use a 135°
bend. 90° bends must not be used, due to their
flow resistance and baffling characteristics.
Ensure that flue pipe entering a brick chimney is
cut off flush with the inside surface or at a small
inclined angle to prevent droppings entering the
flue connection. Provision for cleaning the
chimney should be made below the flue entry.
Refer also to Section 2 of these Instructions.
a) Unpack the boiler.
b) Select the desired oil feed position and remove
the appropriate knockout in the base using a
suitable drift.
c) Position boiler.
d) Lift off top casing panel.
e) Carefully remove knockout panel in top
casing panel using gentle manipulation.
f) Seal flue pipe to boiler with fire cement.
g) Re-fit top casing panel.
Connecting the Electricity Supply
Electrical Connections:
All electrical wiring must be carried out by a
qualified electrician in accordance with current
I.E.E. Regulations and any Local Regulations that
may apply.
Earthing: It is essential that the appliance is
earthed.
Cable Entry: The cable should be heat resisting
and routed either along the top side of the casing
or run from the bottom side through the knock
out holes in the base tray, making sure they do
not come in contact with the heat exchanger.
Fusing: The mains electrical supply should be
taken from a double pole isolating switch (fused
5 amp) situated near the boiler.
Fig. 13
Installation & Commissioning

20 Part No. 5105707Installation & Commissioning
Fig. 14
Wiring Diagrams: Refer to wiring diagrams in
Section 1 of these Instructions. The mains inlet
plug is provided in the bag of fittings supplied.
To wire in external controls, open the door on the
right hand side of the facia panel, to expose a
blanking plate .
Remove the blanking plate you will then see a
plug-in terminal block, remove the appropriate
part, run wires through hole in panel, wire into
plug refit plug into socket, pull through excess
wires then refit blanking plate.
Facia Door
A plastic facia door is incorporated into the
control panel. This door is designed to come
off if any undue pressure is exerted on it when
open but can easily be snapped back into
place.It may however become detached if the
appliance has been handled roughly during
transit. If you find the door is missing when
opening the carton, check to see if it is
amongst the packaging.
Fuel Pipes
Refer to Section 2, Figs. 9, 10, 11 plus Tables
4 and 5.
Before connecting a flexible hose to the burner
draw off a small quantity of oil, approximately
two pints, into a suitable container, check that
fuel is clean.
The flexible fuel pipe should be connected to
the burner and the other end to the fuel line
via the isolation valve (supplied).At this stage
the connection should be left finger-tight as
it will have to be disconnected before the
burner is started in order to vent air from the
line after the fuel has been turned on. Couple
a filter to the rigid pipe and run pipework from
the inlet of the filter to the tank. The filter
should not be installed inside the boiler.
Remove
Front Cover
Control
Panel
Control
Panel Burner
Socket
Mains
Socket
Control Box
Assembly
Control Box
Assembly
Earth
ST00209A
NEL
Live
Neutral
Main Supply
Connection
Limit Thermostat
Reset Button