Potterton Statesman System L 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.
AboutSafety 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
System L,
Flowsure L, Flowsure + L
Installation & Service Instructions

2Part No. 5106463Contents
Contents
Section 1 -Technical Data............................................4
Health & Safety Information.......................................4
System Components................................................5
Boiler Wiring Diagrams............................................9
Technical Data.......................................................12
Boiler Dimensions & Clearances..............................13
Flue Layouts..........................................................14
Section 2 - Pre-Installation Requirements..................15
Chimneys/Flues.....................................................16
Combustion &Ventilation Air Requirements...............17
Balanced & Low LevelTerminal Clearances...............18
Oil Tanks & Layouts................................................20
Floor Temperatures.................................................22
Sealed System Requirements.................................22
Section 3 - Installation & Commissioning..................26
Conventional Flue..................................................27
Electricity Supply...................................................27
Fuel Pipes.............................................................28
Wiring Diagrams.....................................................29
Water Connections.................................................31
Commissioning...................................................33
Section 4 - Servicing & Maintenance..........................36
Servicing...........................................................36
Maintenance......................................................37
Replacement of Parts.............................................37
Thermostats - Statesman System..........................38
Limit Thermostat....................................................38
Boiler Control Thermostat........................................38
Thermostats - Statesman Flowsure/Flowsure+..........39
Boiler Control Thermostat........................................39
Limit Thermostat....................................................39
Pump Overrun Thermostat......................................39
Tank Limit Thermostat.............................................39
DHW Overheat Thermostat......................................39
Heatstore Thermostat.............................................39
Automatic Air Vent..................................................39
Pressure Relief Valve..............................................40
Circulating Pump....................................................40
Expansion Vessel...................................................40
Pressure & Temperature Gauge...............................40
Diverter Valve.........................................................40
Flow Switch...........................................................40
Domestic Service Cock...........................................41
Flow Restrictor.......................................................41
DHW Hot Water Plate Heat Exchanger......................41
Section 5 - Fault Finding...........................................44
Burner does not start, motor does not run..................44
Burner starts, no flame established, no
oil to burner............................................................44
Burner starts, no flame but oil to burner.....................45
Burner starts, flame established but goes to
lockout after 15 seconds.........................................45
Locks out in mornings only......................................45
Flame established but not maintained......................46
Burner runs but smoke, and or smell,
and or pulsation......................................................46
Other problems......................................................47
Section 6 - Spare Parts..............................................48
Section 7 - Flue Kit Options.......................................50

Part No. 5106463 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. 5106463Technical 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 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.
Statesman System
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. 5106463 5Technical Data
Statesman System, Flowsure & Flowsure+
Principal boiler components
Automatic and Manual Air Vents
Manual air vents are provided on the Flowsure and
Flowsure+ only.
Pressure Relief Valve
This is factory set at 3 bar (45 lb/in²).
Pump
An integral circulating pump is incorporated within
the boiler casing.This also serves the functions of
both the central heating circuit and domestic hot
water (Flowsure/Flowsure+).
ExpansionVessel
A 10 litre expansion vessel, charged to 0.5 bar and
is suitable for a static head of 5 metres (16.5 ft), is
included within the boiler casing.
Diverter Valve
On the Flowsure and Flowsure+, a motorised
diverter valve is located on the pump outlet. The
valve is normally closed to the central heating circuit
and is powered open when there is a demand for
central heating via the room thermostat.
Flow Switch
On the Flowsure and Flowsure+, the domestic
mains water inlet is connected to a flow switch, this
detects when a domestic hot water tap has been
opened. This activates the burner and pump.
Domestic Service Cock
The domestic service cock fitted to the mains water
inlet of the Flowsure and Flowsure +, incorporates
a pre-set flow regulation device, this restricts the
maximum flow of domestic hot water to the taps,
13 l/m and 17.5 l/m respectively.
Domestic Hot Water Heat Exchanger
On the Flowsure and Flowsure+, a water to water
heat exchanger is located within the boiler casing.
Primary water is pumped from the boiler (heatstore
tank on Flowsure+) to the heat exchanger whenever
there is a flow of domestic water through a hot water
tap. The domestic water thereby extracts the heat
from the plate heat exchanger giving mains
pressure domestic hot water.The domestic hot
water temperature can be increased by reducing
the water flow rate at the tap (Flowsure) or adjusting
the hot water mixing valve to a higher setting
(Flowsure+).
Pump overrun
On the Flowsure and Flowsure+, a pump overrun
facility has been incorporated into the electrical
control panel which allows excess heat to be
dissipated to either the central heating circuit or
boiler shell, dependant on mode selected.This
prevents the possibility of the boiler overheating.
Heatstore tank
On the Flowsure+, the heatstore tank is a heatbank
containing 40 litres (8.8 gallons) of primary hot
water. The tank temperature is controlled by the
DHW thermostat to approximately 75 °C.
Note: A bypass system should be fitted between
the flow and return pipes, where primary water
flow may be prevented during a pump overrun
situation (Flowsure, Flowsure+).
DHW Mixing Valve (Flowsure+ Only)
The DHW mixing valve is factory set to the mid
position, this will give a blended water temperature
of approximately 60°C. After removing the front
casing (Pull forward off the mounting clips), the
control knob (top right, behind control panel) will
be accessible and can be turned as required.
Clockwise to decrease and anti-clockwise to
increase temperature - See Fig. 4. for the position
of the valve.
MIN Mid
Position Fully Open
Turn the
Control Knob
anti-clockwise
3 notches for
mid position
60˚ Approx. + Temp.
- Temp.
Turn the
Control Knob
anti-clockwise
3 notches for
fully open position
ST00193A
Fig. 1

6Part No. 5106463Technical Data
Fig. 2
ST00206A
C O
M
P
A
C
T
Automatic
Air Vent
Pressure
Relief Valve
Thermostat
Pocket
Control
Thermostat
Main Facia
Panel
Indictator
Lights
Pump
Expansion
Vessel
Expansion
Vessel
Connection &
Boiler Drain Valve
Burner Air
Inlet Pipe
Burner
Lockout
Reset
Button
Burner Oil
Feed Pipe
Knock-out Blanks For
Cables And Fuel Pipes
Thermostat
Pocket
Programmer
(Optional)
Expansion Vessel Cradle
Pressure and
Temperature Gauge
Expansion Vessel
Connection Pipe
Combustion Chamber
Viewing Window
Combustion Chamber
Access Panel
Flow
(22mm)
Return (1" B.S.P.)
Left & Right-hand
Statesman System
Conventional
Flue

Part No. 5106463 7Technical Data
Fig. 3
ST00257A
Cold Water
Feed (15mm)
D.H.W. Flow
(15mm)
C.Heating
Flow (22mm)
NOT
Supplied
Viewing
Window
Automatic
Air Vent
Manual
Air Vent
Certain Items Removed For Clarity
Conventional
Flue
Pressure
Relief Valve
Pump
Overrun
Pocket
Domestic
Service
Cock
Flow
Switch
(Type 1)
Pump
Boiler
Thermostat
Pocket
Plate
Heat
Exchanger
D.H.W.
Limit
Pocket
Expansion
Vessel Expansion
Vessel
Valve
Expansion
Vessel
Connection
Pipe
Expansion
Vessel Support
Bracket
3 Way
Diverter
Valve
C.Heating
Return (1" B.S.P.)
C.Heating
Return (1" B.S.P.)
Boiler limit Stat
& Temp Gauge
Bulb Pocket
Expansion Vessel
Connection &
Boiler Drain Valve
Double
Check
Valve
System Fill Flexible Hose
(DO NOT use as
a permanent fitting)
System
Fill Pipe
System Fill
Isolation Valve
System Fill
(15mm)
Cold Main
Isolation Valve
Flow Switch
(Type 2)
Statesman Flowsure

8Part No. 5106463Technical Data
Fig. 4
Automatic
Air Vent
Mixing
Valve
Pressure
Relief Valve
Boiler
Thermostat
Pocket
Pump
Pump Overrun
Pocket
ST00258A
Primary Water
Heatstore
Heatstore
Drain Valve
Temp./Press Valve
Connection Point
Heatstore
Thermostat
Cold
Water
Feed
(15mm)
D.H.W.
Flow
(15mm)
C.Heating
Flow (22mm)
NOT
Supplied
NOT Supplied
Manual
Air Vent
Certain Items Removed For Clarity
Conventional
Flue
Boiler Limit
Stat & Temp
Gauge Bulb
Pocket
Tank Limit
Stat
Pocket
Plate Heat
Exchanger
Plate Heat
Exchanger
Expansion
Vessel
Connection &
Valve
Expansion
Vessel
Connection
Pipe
Expansion
Vessel
Support
Bracket
Expansion
Vessel
Expansion
Vessel
Valve
3 Way
Diverter
Valve
Double
Check
Valve
C.Heating
Return (1" B.S.P.) System Fill Flexible Hose
(DO NOT use as
a permanent fitting)
System
Fill Pipe
System Fill
Isolation Valve
System Fill
(15mm)
Cold Main
Isolation Valve
Flow Switch
(Type 2)
Domestic
Service
Cock
Flow
Switch
(Type 1)
Statesman Flowsure +

Part No. 5106463 9
Fig. 5
ST00247A
Colour Coding
For The Wiring
b - Blue
br - Brown
gy - Grey
r - Red
bl - Black
g/y - Green/Yellow
Pump
Tray Assembly Link to be replaced with
room thermostat
N
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
bg/y
g/y
br
br
br
r
b
b
g/y
bl
gy
br
br br
r
bl
bl
b
br
b
br
b
b
b
br
NEL
Live
Main
Supply
Connection
LL
E
E
NN
S/L S/L
Neutral
Earth
br
g/y
b
LE
Boiler Wiring Diagram - Statesman System
gy
br
br
g/y g/y
bb
Technical Data

10 Part No. 5106463Technical Data
Fig. 6
3
2
ST00251A
N
L
N
L
N
L
N
N
E
E
L
L
N
N
L
N
L
N
L
Terminal
Block
Terminal
Block
0.47 UF Capacitor
Overheat
Burner
Lockout
Mains
On
NEL
Burner
Socket
Main
Socket
Chassis
Earth
Limit
Stat.
Boiler
Stat.
Pump
Overrun
Stat.
D.H.W.
Thermostat
L2
L1
E
N
21
34
2
22
2
3
Main
Supply
Connection
Colour Coding
For The Wiring
b - Blue
br - Brown
gy - Grey
r - Red
g/y - Green/Yellow
w - White
v - Violet
y - Yellow
o - Orange
p - Pink
bl - Black
b
g/y
br
r
b
b
g/y
bl
br
br
NEL
Live
Main Supply
Connection
L
N
S/L
S/L
Neutral
Earth
11(1)
31(11)
A2(10) A1(2)
14(3)
34(9)
12(4)
32(8)
22(5) 24(7)
21(6)
Flow
Switch
Diverter Valve
Pump
Tray Assembly
L
L
1
1
E
E
N
N
L
L
S/L
S/L
L
L
L
N
E
Relay
br
br
vo
b
g/y
gy
gy
y
o
r
v
o
br
bl
bl
o
r
br
br
br
br
br
b
b
b
bl
bl
bb
p
b
g/y
b
b
br
p
gy
w
g/y
g/y
w
gy
bl
br
br
r
bl
y
b
b
LINK to be replaced
with room thermostat
L
N
CH
ON
HW
ON
1
1
1b1a
1a
o
Electro-mech.
Clock
3 Position Switch
2 Position Switch
53 21
C.Heating
Boiler
b
br
br
gy
p
w
w
br
y
y
b
b
y
br
br
br
br
Boiler Wiring Diagram - Statesman Flowsure
Boiler Functional Flow - Statesman Flowsure
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Part No. 5106463 11
Fig. 7
Technical Data
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Boiler Wiring Diagram - Statesman Flowsure +
Boiler Functional Flow - Statesman Flowsure +
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
Limit
Stat.
Boiler
Stat.
Pump
Overrun
Stat.
Tank Limit
Thermostat
L2
L1
E
N
21
34
2
22
2
3
4
3
2
Main
Supply
Connection
bg/y
br
r
b
b
g/y
bl
br
br
NEL
Live
Main Supply
Connection
L
N
S/L
S/L
Neutral
Earth
11(1)
31(11)
A2(10) A1(2)
14(3)
34(9)
12(4)
32(8)
22(5) 24(7)
21(6)
Flow
Switch
Tank
Thermostat
Diverter Valve
Pump
Tray Assembly
L
L
1
1
E
E
N
N
L
L
S/L
S/L
L
L
L
N
E
Relay
12
br
br
v
v
o
g/y
gy
o
r
v
o
br
bl
bl
o
r
br
br
br
br
br
b
b
b
bl
bl
bb
p
b
g/y
b
b
br
p
w
g/y
g/y
w
gy
bl
br
br
r
bl
gy
gy
0.47 UF Capacitor
LINK to be replaced
with room thermostat
L
N
CH
ON
HW
ON
1
1
1b1a
1a
o
Electro-mech.
Clock
3 Position Switch
2 Position Switch
53 21
C.Heating
Boiler
b
br
br
gy
p
w
w
br
y
y
b
bb
yy
y
b
b
y
br
br
br
br
Colour Coding
For The Wiring
b - Blue
br - Brown
gy - Grey
r - Red
g/y - Green/Yellow
w - White
v - Violet
y - Yellow
o - Orange
p - Pink
bl - Black
ST00252A

12 Part No. 5106463Technical Data
Table 1
Technical Data
Model
Btu/h kW Btu/h kW Btu/h kW
Maximum Output 89,000 26 89,000 26 89,000 26
Minimum Output 68,000 20 68,000 20 68,000 20
Factory Set Output Kerosene 79,000 23 79,000 23 79,000 23
Riello Burner Type RDB1 RDB1 RDB1
Combustion Head Type Kerosene LD3 LD3 LD3
Gas Oil LD3 LD3 LD3
Nett Full Load Efficiency %91.0 91.0 91.0
Boiler Gas Volume m³ 0.058 0.058 0.058
Exit Flue Gas Mass Flow (Max) k
g
/h 40.09 40.09 40.09
Flue Gas Temperature Rise Above Ambient ºC 205 205 205
Resistance To Combustion Products mbar 0.4 0.4 0.4
Maximum Hearth Temperature ºC 50 50 50
Water Side Resistance (Cold)
10ºC Differential mbar 21.2 21.2 21.2
20ºC Differential mbar 6.7 6.7 6.7
Maximum Static Head 90ft. Water (40 p.s.i.)
Minimum Static Head 5.0ft. Water (3.0 p.s.i.)
Maximum Operating Temperature 82ºC (180ºF)
Minimum Operating Temperature 55ºC (131ºF)
Maximum Boiler Operating Pressure 3 Bar (43.5 p.s.i.) (Class 2)
Conventional Flue Draught at Boiler Flue Outlet 0.035"w.
g
. (8.75N/m²) Minimum 0.16"w.
g
. (40.0N/m²) Maximum
Limit Thermostat Setting 110ºC (230ºF) Manual Reset
Maximum Casing Panel Temperature Less Than 35ºC Above Room Temperature
Maximum Surface Temperatures of
Adjusting, Control & Safety Devices Less Than 30ºC Above Room Temperature
Electrical Supply 230V 1 Phase 50Hz Fuse 5A
DHW Limit Thermostat Setting 85ºC (185°F)
DHW Store Thermostat Setting 73ºC (163F)
DHW Store Limit Thermostat Setting 88ºC (190ºF)
Pump Overrun Thermostat Setting 80ºC (176ºF) 88ºC (190ºF)
Flow Restrictor 13 l/m (Brown) 17.5 l/m (Green)
Maximum DHW Flow Rate 13 ± 1.5 l/m (2.9 ± 0.3
g
/m) 17.5 ± 1.5 l/m (3.9 ± 0.3
g
/m)
Minimum DHW Flow Rate 2.5 ± 0.5 l/m (0.5 ± 0.1
g
/m) 2.5 ± 0.5 l/m (0.5 ± 0.1
g
/m)
Maximum DHW Inlet Pressure 10 Bar (145 p.s.i.) 10 Bar (145 p.s.i.)
Minimum DHW Inlet Pressure 1 Bar (14.5 p.s.i.) 1 Bar (14.5 p.s.i.)
Specific Rate at Minimum Heat Input (20 kW) 9.5 l/m (2.1
g
/m) 12.5 l/m (2.7
g
/m)
DHW Temperature Rise At a Constant 35ºC 8.5 l/m (1.9
g
/m) 11.0 l/m (2.4
g
/m)
50ºC 5.5 l/m (1.2
g
/m) 7.0 l/m (1.5
g
/m)
Specific Rate at MId Heat Input (23 kW) 11.0 l/m (2.4
g
/m) 14.0 l/m (3.1
g
/m)
DHW Temperature Rise At a Constant 35ºC 9.5 l/m (2.1
g
/m) 12.0 l/m (2.6
g
/m)
50ºC 6.5 l/m (1.4
g
/m) 8.5 l/m (1.9
g
/m)
Specific Rate at Maximum Heat Input (26 kW) 12.0 l/m (2.6
g
/m) 17.0 l/m (3.7
g
/m)
DHW Temperature Rise At a Constant 35ºC 10.5 l/m (2.3
g
/m) 14.5 l/m (3.2
g
/m)
50ºC 7.5 l/m (1.6
g
/m) 10.0 l/m (2.2
g
/m)
Thermal Store Capacity 40 Litres
Time to Achieve Storage Temperature at Max Heat I/P 7 Minutes (From Cold) 13 Minutes (From Cold)
Flowsure+ 70/90System 70/90 Flowsure 70/90

Part No. 5106463 13
Model
Height
Width
Depth
Centre of flue from rear
Flue Diameter
Height of bottom connection
Distance of conn. from wall
Return Connections 2off
1 off
Flow connections 1 off
Cold Mains Inlet
DHW Outlet
System Fill
Weight empty
Water content
Water content
Oil Supply Connection
Installation Front
Clearances Top
Sides BF
Sides CF
mm
mm
mm
mm
mm
mm
mm
kg
ltr
Imp
BSP
mm
mm
mm
mm
A
B
C
D
E
G
H
J
K
System
850
490
565
100
125
97
59
1" B.S.P
22mm
130
20.5
4.5
¼"
610
12*
6
25
Flowsure
850
490
565
100
125
97
59
1" B.S.P
22mm
15mm
15mm
15mm
145
20.5
4.5
¼"
610
12*
6
25
Flowsure+
850
590
565
100
125
97
59
1" B.S.P
22mm
15mm
15mm
15mm
170
60.0
13.2
¼"
610
12*
6
25
* If mounted under a worktop, the top needs to be removed
Table 2
Boiler Dimension & Clearances
SEDBUK Declaration for Statesman
(Gas Oil - Mid Range)
Model Seasonal Efficiency
(SEDBUK) (%)
System 85.5
Flowsure 82.7
Flowsure + 82.9
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.
SEDBUK Declaration for Statesman
(Kerosine)
Model Seasonal Efficiency
(SEDBUK) (%)
System 85.1
Flowsure 82.3
Flowsure + 82.3
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.
Technical Data

14 Part No. 5106463
ST00259A
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)
Kit 3 2.150m Min.
4.550m Max.
20mm
Flue
Outlet
Flue
Outlet
Flue
Outlet
C
D
D
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 Flue Kits 3, 5, 6, 7, & 8 Flue Kits 3, 4, 5, 6, 9 & 10
Kits 5 & 6 (if required)
Fig. 8
Technical Data

Part No. 5106463 15
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
01926 430481. 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. 9
Pre-Installation Requirements
2 - Pre-Installation Requirements

16 Part No. 5106463Pre-Installation Requirements
Fig. 10
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. 5106463 17
Fig. 11
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

18 Part No. 5106463Pre-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. 12
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. 5106463 19
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. 13
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
Clearances Required Around Balanced and Low Level Discharge Flues Fitted to Oil Fired Boilers
Pre-Installation Requirements
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.

20 Part No. 5106463Pre-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. 14