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.

 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 All boilers can be supplied with either of the following types
wall mounted fan powered balanced flue appliances, using of flue system:
a cast iron heat exchanger and are available in five outputs
ranging from 5.86-23.44kW (20,000-80,000 Btu/h). 1) Standard horizontal flue system suitable for wall
thickness of 100mm (4 in.) to 510mm (20 in.).
The boilers which are designed to provide domestic hot 2) 2 metre horizontal flue system which provides a
water and/or central heating must be used on INDIRECT maximum flue length Of 1955mm (77 in.).
hot water systems only. The cast iron heat exchangers are 3) Vertical flue system which allows the flue to pass
suitable for use on open vented gravity domestic hot through a flat roof and terminate at a maximum height
water/pumped central heating systems or fully pumped of 1980mm (78 in.) measured from the top of the boiler
systems which may be sealed or open vented. case.

OPTIONAL EXTRAS - Page 2

The following are kits available as optional extras:—
Internal Fitment Kit, which is suitable for a maximum wall P.I.L. PART Nos.
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.
ACCESSORIES - Page 3
The following Potterton Myson controls are recommended Motorised Zone Valve M5V222 or M5V228
for use with your boiler:- Motorised Diverter Valve M5V322
Electronic Programmer EP2001, EP3001, or EP6000 Thermostatic Radiator Valve
Cylinder Thermostat PTT2 or PTT1 00 Data sheets describing these products are available on
Room Thermostat PRT2 or PRT1 00 request.
Frost Thermostat PRT1 00 FR

INSTALLATION DATA - Page 3

The installation of the boiler must be in accordance with the B55440 Part 2 B55449 Part 1
latest relevant requirements of the Gas Safety (Installation B55546 B5481 4. B56891.
and Use) Regulations, local building regulations, lEE Wiring BUILDING REGULATIONS.
Regulations and the Byelaws of the Local Water MODEL WATER BYELAWS.
Undertaking. BRITISH GAS PUBLICATION DM2.
GAS SAFETY (INSTALLATION AND USE)
Detailed recommendations are contained in the following REGULATIONS.
British Standards and Codes of Practice. BUILDING STANDARDS (SCOTLAND)
REGULATIONS.
BS6798, B55440 Part 1

BOILER DIMENSIONS - Page 3

R.c ½

*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 installation of the appliance in a room containing a bath or
should not be fitted directly above a cooking appliance. The shower.
boiler may be installed in any room, although particular
attention is drawn to the requirements of the current I.E.E. Where a room-sealed appliance is installed in a room
Wiring Regulations and in Scotland, the electrical provisions containing a bath or shower, any electrical switch or
of the Building Standards applicable in Scotland with appliance control, utilising mains electricity should be so
respect to the situated that it cannot be touched by a person using the
bath or shower.
SITE REQUIREMENTS - Page 4

FIG. 2 GENERAL ARRANGEMENT

SITE REQUIREMENTS - Page 5
Where the installation of the boiler will be in an unusual 50mm (2 in) at the top (measured from the top of the boiler
location, special procedures may be necessary and BS 6798 case), except where the optional extra pump cover is to be
gives detailed guidance on this aspect. fitted, when 178mm (7 in) should be allowed.

Ensure that the gas supply pipe and meter are large enough 100mm (4 in) at the bottom of the boiler.
for this appliance and any others that may be run off the
same meter. Reference should be made to B56891 Additional clearances to these are required during
installation for lifting the boiler and 127mm (5 in) is required
Boiler Mounting Surface at the top of the boiler for access to the pipe connections.
The boiler must be mounted on a flat wall, which may be of
combustible material and must be sufficiently robust to take Ventilation
the weight of the boiler. The requirements of the local If the boiler is to be installed in a confined space such as a
authorities and the Building Regulations must be adhered to. cupboard, the space will need ventilating. Openings must be
provided at the top and bottom of the Cupboard each of
IMPORTANT NOTICE: which should have a free area as shown in TABLE 1. Further
TIMBER FRAMED HOUSES details for installation of a boiler within a compartment are
given in BS 6798.
If the appliance is to be fitted in a timber framed building, it
should be fitted in accordance with British Gas Publication TABLE 1
‘Operational Procedures for Customer Service’ Part 19. If in AIR VENT AREAS
any doubt, advice should be sought from the local region of PROFILE
British Gas. in2 cm2
30e 16 103
Clearances Around the Boiler 40e 21 135
The following minimum clearances must be maintained after 50e 26 170
installation, for correct operation and servicing of the boiler: 60e 32 206
80e 43 277
610mm (2 ft) at the front of the boiler
If the openings draw air from outside the building the free
5mm (0.2 in) each side of the boiler areas may be halved. Refer to BS 5440 Part 2 for further
guidance.
Balanced Flue Terminal and Ducting
INFORMATION RELATING TO VERTICAL FLUING IS
The fresh air inlet and flue ducts can be run from either the PROVIDED IN THE PACK CONTAINING THE VERTI-CAL
left, right, rear or top of the boiler to a miniature terminal on FLUE SYSTEM.
the outside of the building.
NOTE
The minimum spacings from the terminal to obstructions and Where a flue terminal is fitted less than 1000mm from a
ventilation openings are shown in FIG. 3. For information plastic or painted gutter or 500mm from painted eaves, an
appertaining to horizontal flue lengths reference should be aluminium shield of 1000mm length should be fitted to
made to FIG. 4. underside of gutter or eaves.

If a terminal is fitted less than 2m above a balcony, above Any car port or other add-on extension should consist of a
ground or above a flat roof to which people have access roof or a roof and one other wall. If it consists of a roof and
then a suitable terminal guard should be fitted. (P.l.L. No. two other walls − the installation shall be treated as suspect
205792). and further advice sought.

Refer to B55440 Part 1 for further guidance. 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
FIG. 3 THE SITING OF BALANCED L. HORIZONTALLY FROM A TERMINAL ON
FLUE TERMINALS THE SAME WALL 300
M. ADJACENT TO OPENING 150
SITE REQUIREMENTS - Page 6
ALL MODELS REAR OR SIDE FLUEING

MAXIMUM
LENGTH ‘X’
STANDARD FLUE 510mm
SYSTEM (20in)
1 METRE FLUE 955mm
SYSTEM (37in)

FIG. 4 FLUE LENGTHS

ELECTRICITY SUPPLY

A 240 volts -~ 50Hz, single phase electricity supply fused to The supply to the boiler and its associated equipment should
3 amperes, must be provided in accordance with the latest be controlled by an exclusive 3A fused double pole switch
edition of the I.E.E. Wiring Regulations and any other local (having at least 3mm contact separation in both poles) so that
regulations that may apply. The current rating of the wiring complete isolation from the supply can be achieved to enable
to the boiler must exceed 3 amperes and have a cross servicing work to be carried out in safety.
sectional area of at least 0.75mm2 in accordance with
B56500 Table 16.

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 820C 80e
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)
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 TABLE 2

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.

FIG. 5 PRESSURE LOSS ACROSS BOILER

SITE REQUIREMENTS - Page 8
The System necessary. The total length of the by-pass circuit taken from the
boiler connections should be greater than 4 metres of 22 mm pipe.
The boiler must be used on INDIRECT hot water systems only. It is It should be fitted with a lockshield valve and be adjusted to
suitable for use on open vented gravity domestic hot water/pumped maintain a minimum flow through the boiler of 4.5 litres/mm (1
central heating systems or, fully pumped systems which may be gal/mm) see FIGS 6, 7.
sealed or open vented.
Systems fitted with controls which allow the boiler to operate when
The system should be designed so that the maximum static head both the hot water and central heating circuits are closed i.e.
does not exceed 30.5 m (100 ft) and a minimum on fully pumped mechanically operated thermostatic control valves, must be fitted
systems of 305 mm (1 ft). See FIG. 6. with a by-pass circuit capable of:—

Gravity domestic hot water circuits should have a minimum 1. Dissipating a minimum of 1 kW (3400 Btu/h)
circulating head of 1.2 m (4ft). See FIG. 8. 2. Maintaining a minimum water flow through the boiler of 9
litres/mm (2 gal/mm).
To ensure optimum boiler performance on both gravity hot water
and fully pumped systems a change-over switch is incorporated in A suggested method of meeting these requirements by using a
the boiler control box. The boiler is supplied with the switch set for bathroom radiator fitted with two lockshield valves is shown in
sealed or open vented fully pumped systems. FIGS. 6, 7.

If the boiler is to be used on a system with gravity hot water the Additional system information can be found in the Control Systems,
switch should be set at the GRAVITY position. In addition the bulb Pipework and Wiring Guide.
of the overheat thermostat should be repositioned as shown in
FIG. 21. SEALED SYSTEMS (FULLY PUMPED)

To prevent reverse circulation in the gravity circuit when the pump Installation
is running an injector disc is provided to form an injector tee at the
return connection on the boiler. See FIG. 20. The installation must comply with the requirements of BS 6798 and
BS 5449 Part 1. The B.G. publication “British Gas Specification for
On all systems the pump should be wired to the boiler terminal Domestic Wet Central Heating Systems” should also be consulted.
block. To prevent nuisance operation of the overheat thermostat, it
is important that where electrically operated zone valves are used Safety Valve
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 A non adjustable spring-loaded safety valve, preset to operate at 3
and central heating circuits while the boiler is still hot, must be bar (451bf/in2) shall be used. It must comply with BS 6759 Part 1
fitted with a by-pass circuit to dissipate the residual heat within the and include a manual testing device. It shall be positioned in the
boiler. flow pipe either horizontally or vertically upwards and close to the
boiler. No shut-off valves are to be placed between the boiler and
Further information on by-pass arrangements is provided in later the safety valve. The valve should be installed into a discharge
notes and illustrations. pipe which permits the safe discharge of steam and hot water such
that no hazard to persons or damage to electrical components is
Drain off taps should be fitted in the pipework close to the boiler caused.
and in the low points of the system.
Pressure Gauge
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 A pressure gauge incorporating a fill pressure indicator, covering
necessary to remove the drain off cap positioned within the boiler the range 0-4 bar (60 lbf/in2) shall be fitted to the system. It should
case. See FIG. 2. be connected to the system, preferably at the same point as the
expansion vessel. Its location should be visible from the filling
Combined Gravity Hot Water Pumped Central Heating point.
Systems. Where a cylinder thermostat and zone valve is used to
control the temperature of the hot water it is recommended that a Expansion Vessel
by-pass be installed in the gravity circuit. A suggested method of
doing this is shown in FIG. 8 where the bathroom radiator is A diaphragm type expansion vessel to B54814 Part 1 shall be fitted
connected into the gravity circuit and is fitted with two lockshield close to the inlet side of the pump. The connecting pipework
valves. Mechanically operated thermostatic domestic hot water should not be less than 15 mm (½ in nominal). Pipework
temperature control valves which allow the boiler to operate when connecting the expansion vessel should not incorporate valves of
the valve is closed or partially closed MUST NOT BE FITTED. any sort. Methods of supporting the vessel are supplied by the
manufacturer. The nitrogen or air charge pressure of the expansion
Fully pumped Systems vessel shall not be less than the hydrostatic head, (height of the
top point of the system above the expansion vessel). To size the
With the change-over switch in the control box set at the FULLY expansion vessel it is first necessary to calculate the volume of
PUMPED position, the pump will be controlled by an over-run water in the system in litres. The following volumes may be used
thermostat. This will ensure that the pump will continue to run after as a conservative guide to calculating the system volume.
boiler shut down if the water temperature in the boiler is high, thus
preventing nuisance operation of the overheat thermostat. Boiler Heat Exchanger: 6.5 litres
Small Bore Pipework: 1 litre per kW of
If a three port diverter valve is used as shown in FIGS. 6, 7 a by- system output
pass is not necessary since one circuit is always open. Micro Bore Pipework: 7 litres
Steel Panel Radiators: 8 litres per kW of
Where a pair of two port valves are used, a by-pass is system output
Low Water Capacity Radiators: 2 litres per kW of
system output
Hot water Cylinder: 2 litres
SITE REQUIREMENTS - Page 9
If the system is extended, the expansion vessel volume may Method of Make-Up
have to be increased unless previous provision has been Provision shall be made for replacing water loss from the
made for the extension. Where a vessel of the calculated system either:—
size is not available, the next available larger size should be i) from a make-up vessel or tank mounted in a position
used. higher than the top point of the system, and connected
The boiler flow temperature is controlled at approximately through a non-return valve to the system on the return
820C. side of hot water cylinder or the return side of all heat
emitters.
The vessel size can now be determined from the following or
table where V=System volume in litres. 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
Vessel Charge Pressure(bar) 0.5 1.0 METHODS 1 and 2.

Initial System Pressure (bar) 1.0 1.0 Mains Connection

Expansion Vessel Volume (litres) V x 0.11 V x 0.087 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
Cylinder local Water Authority.

The hot water cylinder must be an indirect coil type or a Filling Point
direct cylinder fitted with an immersion calorifier suitable for
operating at a gauge pressure of 0.3 bar (51 bf/in2) in The system shall be fitted with a filling point at low level
excess of safety valve setting. Single feed indirect cylinders which incorporates a stop valve to BS1 010 and a double
are not suitable for sealed systems. 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
SITE REQUIREMENTS - Page 10

FIG 7. FULLY PUMPED SEALED SYSTEM

FIG 8. OPEN VENTED GRAVITY DOMESTIC HOT

WATER AND PUMPED CENTRAL HEATING SYSTEM
INSTALLATION INSTRUCTIONS - Page 11
It is the law that all gas appliances are installed and CARTON 2:- Flue System Pack Standard and 2 metre
serviced by competent persons as stated in Gas Horizontal Flue Packs
Safety (Installation and Use) Regulations 1994. Air/Flue Duct Assembly (length as ordered)
For Health and Safety information see back page. Flue Elbow Extension
Flue Terminal
Electrical installation and servicing should be carried out by Flue Sealing Collar
a competent person in accordance with the I.E.E. Wiring Rope Sealing Ring
Regulations. Side Infill Panels-2 off
The boiler and its associated equipment will arrive on site in
two cardboard cartons. The contents of each carton is as Vertical Flue Pack (2 cartons)
follows. Air/Flue Duct Assembly
Flue Terminal
CARTON 1:- Boiler Pack Terminal Cowl
Boiler Vertical Flue Adapter
Template Accessory Pack
Literature Pack Containing:- Side Infill Panels-2off
Installation and Servicing Instructions Flue Installation Instructions
User’s Instructions
Control Systems Pipework and Wiring Guide
Auxiliary Pack Containing:-
Boiler Mounting Bracket
Gas Service Cock and Accessory Packs

FIG. 9 TEMPLATE
FIG. 10 BOILER MOUNTING PLATE
Place template in proposed boiler position ensuring it is
level (the minimum side clearances are automatically Remove template and carefully cut flue outlet hole through
allowed for) wall. If necessary make good around hole to enable holes
‘B’ to be drilled. (If internal flue fitment kit is being used refer
REAR FLUING to instructions supplied with kit).
Drill holes ‘A’ using a 7 mm drill
Mark holes ‘A’, ‘B’, ‘D’, large flue outlet hole and side of Drill holes ‘B’ and ‘D’ using a 5 mm drill
boiler reference lines throught slots ‘C’.
Using wall plugs, screws and washers (accessory pack A)
SIDE FLUING attach boiler mounting plate to wall. Ensure that it is level
and the correct way up, i.e. to provide the clearance at the
Mark hole positions ‘A’, ‘D’ and side of boiler reference lines rear of the boiler allowed for when marking out using the
through slots ‘C’. template. See also NOTE on FIG. 1.

Mark large flue outlet hole and holes ‘B’ using the thick lines Insert wall plugs into holes ‘B’ (accessory pack B) and hole
on the template for minimum clearance at the rear of the ‘D’ (accessory pack D).
boiler and the thin dotted lines for maximum clearance. See
NOTE on FIG. 1. Insert flue sealing collar into wall and secure with screws
provided, (accessory pack B). Make good the internal wall
surface around flue sealing collar.
INSTALLATION INSTRUCTIONS - Page 12
CUTTING AIR/FLUE DUCTS

FIG. 11a SIDE FLUE FIG. 11b REAR FLUE

1. Measure from outside face of wall to the side of boiler 1. Measure wall thickness (dimension ‘Y’).
casing reference line (dimension ‘x’). 2. Take air/flue duct assembly and measuring from the
2. Take air/flue duct assembly and measuring from the flanged end, mark and cut the outer air duct and inner
flanged end, mark and cut the outer duct and inner flue flue duct to dimension ‘Y’, plus 45 mm. Ensure that
duct to dimension ‘x’ plus 20mm. Ensure that both both ducts are cut squarely.
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 3. Engage four screws from accessory pack ‘C’ into the
so arranged that when installed, the seam in the duct will be pre-drilled holes in the terminal and screw fully home.
uppermost. These screws which are self drilling will pierce the air
duct and secure the terminal to air duct.
1. Slide rope sealing ring on to air duct.
2. Engage the terminal on to the ends of the inner flue On models 30e, to 50e, it is necessary to drill four pilot
duct and press fully home. holes in the air duct.
INSTALLATION INSTRUCTIONS - Page 13

FIG. 13 SECTIONAL VIEW OF AIR/FLUE

DUCT ASSY THROUGH WALL
5. Insert the assembly into the wall sliding the rope sealing
4. Protect duct where it is likely to come into contact with ring along the air duct into the flue sealing collar. Bend
mortar by using adhesive tape provided (accessory pack the six tabs on flue sealing collar inwards to retain the
E). 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 plate. Remove the remaining screws securing the fan
unpacking the boiler, if not remove controls cover by opening mounting plate and remove the mounting plate complete
the door covering the securing screw on the underside of the with fan.
controls cover, see FIG. 14. Undo securing screw, pull
controls cover forward 10mm, lower to release from the four Disconnect the two flexible tubes from the flue elbow.
side fixings and pull forward clear of the thermostat knob.
Remove the four brass securing nuts and lift off the flue
Remove door by undoing the two lower fixing screws and lift elbow, taking care not to damage the gasket.
door off the two upper hinge brackets.
NOTE:
Remove the screws securing the combustion chamber front If side fluing, loosen the two brass securing nuts beneath the
panel and remove panel. flue elbow outlet and remove the other two.
Tilt the flange and withdraw the elbow.
Disconnect the fan supply leads from the connector adjacent
to the fan. Leaving in place the three screws identified with a The boiler is supplied with the left hand flue outlet sealing
red circle or adjacent ‘F’ mark in fan plate removed. If another flue outlet direction is required,
remove the appropriate flue outlet sealing plate and transfer
it to the left hand position.
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 Position boiler on its mounting bracket so that the sides of
casing and secure using four wing nuts (accessory pack F). 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. 18 FLUE ELBOW EXTENSION

FIG. 17 SECURING BOILER

Rotate the left hand adjustment screw to align one of the When side fluing, slide the elbow extension onto the elbow
holes in the base plate with hole ‘D’ in the wall. Working and ensure that it is pushed on fully. Engage the screw from
through the hole in the leg, secure the base plate to the wall accessory pack ‘C’ into the pre-drilled hole in the elbow
using the screw from accessory pack D. Make good the wall extension and screw fully home. The screw which is self
surface around the flue terminal. Fit optional terminal wall drilling will pierce the elbow and secure the extension to the
plate if required. elbow.
INSTALLATION INSTRUCTIONS - Page 15

FIG 20. PIPE CONNECTIONS

Connect system pipework to the boiler, compression fittings

FIG. 19 LOCATION OF PRESSURE should be used. If however capillary fittings are used it is
SENSING TUBES essential to temporarily remove the thermostat bulb from the
flow pipe before soldering. A drain off tap should be installed
Slide the flue elbow into the flue duct and locate the flange over close to the boiler if it is in a low point of the system.
the studs on the fluehood ensuring that the sealing gasket is in
place. Secure the elbow to fluehood using the four brass On combined gravity hot water/pumped central heating
securing nuts. Reconnect flexible tubes to elbow. ENSURE installations the flow and return pipes for both the gravity hot
THEY ARE NOT KINKED. NOTE: Red tube connects the front water circuit and pumped central heating circuit must be
aluminium tube in upper chamber to the lower connection on connected to tees fitted directly to the flow and return pipes on
elbow, each being identified with a red ring. 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

INSTALLATION INSTRUCTIONS - Page 16
ELECTRICAL

The boiler and all external control circuit wiring must be

supplied from the same single isolating switch or plug and
socket, and should be fused at 3A.

Care must be taken to ensure that all wiring to the boiler is

kept clear of sharp edges and hot surfaces.

FIG. 21 OVERHEAT THERMOSTAT BULB

POSITION

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

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.

FIG. 23 ACCESS TO THE BOILER ELECTRICAL

TERMINAL BLOCK
INSTALLATION INSTRUCTIONS - Page 17

FIG. 24 ROUTING OF ELECTRICAL WIRING

Following the pump manufacturer’s instructions connect the Gravity Domestic Hot Water/Pumped Central
Heating Systems.
pump supply wires to terminals marked PUMP L,N, ‘ ’-on the
Switched live from external gravity domestic hot water control
boiler terminal block. Route the cable through the plastic bush in
circuit to terminal marked MAINS ‘SwL’. Switched live from
the rear of the control box as illustrated in FIG. 24 and secure,
external pumped central heating control circuit to terminal
using the cable clamp.
marked MAINS ‘L’. Neutral to terminal marked MAINS ‘N’.
Route a four core cable through the plastic bush in the rear of Earth to terminal marked ‘ ’ adjacent to cable clamp. See
the control box and the cable clamp as illustrated in FIG. 24 and NOTE.
connect it to the boiler input terminals as follows:—
If there are no external controls fitted connect the SwL terminal
Fully Pumped Systems. to permanent live in the junction box.
Permanent live to terminal marked MAINS ‘L’.
Neutral to terminal marked MAINS ‘N’.
NOTE:
Earth to terminal marked ‘ ’ adjacent to cable clamp. Ensure that the earth conductor is longer than the L, N & SwL
See NOTE. from the point of anchorage, so that the current carrying
Switched live from external controls to terminal marked conductors become taut before the earth conductor if cable is
MAINS ‘SwL’. pulled out of the cable clamp. When the wiring has been
If there are no external controls fitted connect the SwL completed close the control box and replace the securing screw.
terminal to permanent live in the junction box.

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
COMMISSIONING - Page 18
Open Vented Systems Refit the combustion chamber front panel.
Remove the pump and flush out the system thoroughly
with cold water. Refit the pump. Fill and vent the system. Fit the case door into position by lifting it onto the top hinge
Examine for leaks. brackets and secure it with the lower two fixing screws.

Sealed Systems ENSURE THAT A GOOD SEAL IS OBTAINED

NOTE:
The system can be filled using a sealed system filler pump Remove the temporary label from the front of the casing,
with a break tank or by any other method approved by the having checked compliance with the information it contains.
Local Water Authority. Refer to ‘THE SYSTEM’ section Page
8 in these instructions, also BS 6798 1987. First Lighting
WARNING: Before lighting the boiler, ensure that the CASE
Remove pump and flush out the system thoroughly with cold DOOR HAS BEEN CORRECTLY FITTED and that the
water. Refit the pump. Fill and vent the system until the sealing strip fitted to the case door is forming a tight seal
pressure gauge registers 1.5 bar (21.5 lbf/in2). Examine for with the main boiler casing. Before proceeding to light the
leaks. Raise the pressure until the safety valve lifts. This boiler, check that the external electricity supply to the boiler
should occur within ± 0.3 bar of the preset lift pressure of 3 is switched off and that the boiler thermostat is in the ‘0’
bar. Release water to attain the correct cold fill pressure. position.

All Systems Turn on the gas service cock.

Refit the fan assembly and reconnect the fan supply leads,
(polarity of the fan leads is not important). Ensure that the pump and radiator isolating valves are open.

The whole of the gas installation including the meter should Ensure that the time control, if fitted is in an on condition,
be Inspected and tested for soundness and purged in and that the room and/or cylinder thermostats, where fitted
accordance with the recommendations of BS6891. are set to high temperatures.

Test pilot unions for gas soundness as follows:— Turn boiler Switch on the external electricity supply to the boiler. In the
thermostat to the ‘0’ position. event of an electrical fault after installation of the appliance,
preliminary electrical system checks must be carried out as
Unplug the gas control valve supply lead from the control described in the BG multimeter instruction book. The checks
box and plug it into the test socket adjacent to the boiler to be carried out are:-
thermostat knob, see FIG. 24. A. Earth Continuity
B. Short Circuit
Turn on gas at the gas service cock. C. Polarity
D. Resistance to Earth
Ensure that the time control if fitted is in an ON condition,
and that the room and/or cylinder thermostats where fitted Refer to Fault Finding Chart FIG. 31
are set to high temperatures. Turn the boiler thermostat on and to a high setting and after
a period of time the main burner will light, this can be
Switch on the external electricity supply to the boiler. observed through the sight glass in the front cover of the
boiler. The time period can vary upwards of 45 seconds,
Gas will flow to the pilot only. It will not be ignited as the depending on the amount of air in the pipework.
ignition system is de-energised.
Test for gas soundness around the boiler components using
Using a leak detection fluid, check pilot unions for gas leak detection fluid.
soundness. Turn the boiler thermostat to ‘0’.

Turn off the external electicity supply and gas service cock. NOTE:
Remove gas control valve plug from the test socket and refit There could be a delay in lighting if the control knob is
the plug into the socket on the left hand side of the control switched on and off and then on again rapidly.
box see FIG. 24.

SETTING AND CHECKING OF CONTROLS If burner pressure adjustment is necessary proceed as

With the controls cover removed. follows, referring to FIG. 26.
Fit a pressure gauge to the pressure test nipple in burner
supply pipe. See FIG. 2. WHITE RODGERS GAS CONTROL VALVE
Turn on the boiler thermostat and ensure that the main Remove the brass cover screw from the gas control valve
burner is alight. Check that the burner pressure is in and turn the screw beneath, clockwise to increase the
accordance with values stated under TECHNICAL DATA. pressure or anti-clockwise to decrease the pressure.
The burner pressure is set to the maximum output at the HONEYWELL GAS CONTROL VALVE
factory. Turn the pressure adjustment screw anti-clockwise to
increase the pressure or clockwise to decrease the pressure.
COMMISSIONING - Page 19

FIG. 26 MAIN BURNER PRESSURE ADJUSTMENT

With the burner set to its correct pressure, the firing rate Gravity Hot Water/Pump Over-Run Thermostat
given in TECHNICAL DATA should also be obtained and this The function of this thermostat is determined by the position
should be checked by meter reading at least 10 minutes in which the GRAVITY/FULLY PUMPED SYSTEM selection
after the main burner has been lit. When the pressure and switch is set. The thermostat is pre-set and no adjustment is
rate are correct replace the brass cover screw on WHITE possible.
RODGERS gas control valve. On the FULLY PUMPED switch position it will operate as a
Shut down the boiler remove the pressure gauge and refit pump over-run thermostat and will keep the pump running
the screw in the test nipple ensuring that a tight seal is after the boiler has shut down, as long as the water
made. temperature within the boiler is above approximately 800C.
Remove the self-adhesive arrow from the inspection ticket On the GRAVITY switch position it will operate in series with
tied to the burner supply pipe and stick it to the Data Plate the boiler thermostat when only the gravity domes-tic hot
inside the controls cover to indicate the appropriate burner water circuit is in operation.
setting pressure. It will over-ride the boiler thermostat when the water
Refit the controls cover. temperature within the boiler is above 800 C.
Relight the boiler and heat the system to maximum. Check Overheat Thermostat
for water leaks, turn the boiler off, drain the system whilst The overheat thermostat is pre-set and no adjustment is
hot. possible. It will require manually resetting if an overheat
Refill the system and on sealed systems adjust to the correct condition occurs. Access to the reset button is through a
cold fill pressure. Set the pressure gauge pointer to the hole in the underside of the controls cover, see FIG. 2.
system design pressure. Other Boiler Controls
If a by-pass circuit is fitted the by-pass valve should be All boiler mounted controls are designed so that if any fault
adjusted with the boiler operating under minimum load should occur they will fail safe. No further setting or checking
conditions to maintain sufficient water flow through the boiler is necessary.
to ensure that the overheat thermostat does not operate External Controls
under normal operating conditions. Check that any other external control connected in the
Pilot Burner system, such as clocks and thermostats, control the boiler as
The pilot is pre-set and no adjustment is required. The pilot required.
flame envelope should cover the electrode tip and spark User’s Instructions
earthing strip see FIG. 30. If the pilot flame is not as A User’s Instructions leaflet is provided with this boiler but
illustrated, remove and clean the pilot as described in the the householder must have the operation of the boiler and
Servicing Instructions Section 3, PILOT BURNER, Page 22. system explained by the Installer. The householder must
Boiler Thermostat also be advised of the importance of annual servicing and of
At its minimum and maximum settings, the thermostat the precautions necessary to prevent damage to the system
should control the water flow temperature at approximately and building, in the event of the system remaining out of
550C—820C (1300F—1800 F). commission in frost conditions.
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.
COMMISSIONING - Page 20

FIG. 27 FUNCTIONAL FLOW DIAGRAM

FIG. 28 BOILER WIRING DIAGRAM

SERVICING INSTRUCTIONS - Page 21
Regular skilled servicing and cleaning of the appliance is valves, thermostats, the time control and the expansion and
essential to ensure continued safe and efficient operation. feed water system. It is advisable to clean the boiler
The frequency of cleaning will depend upon the particular immediately after the end of the heating season.
installation conditions, and the use to which the appliance is In all cases prior to servicing, light up the boiler and check
put, but in general, once per year should be adequate. that the pilot and main burners have a clean, even flame and
that the gas rate and main burner pressure are correctly set.
It is the law that all gas appliances are installed and serviced If the pilot flame is satisfactory, no further servicing of the
by competent persons as stated in Gas Safety (Installation pilot burner is necessary and the information given in ‘3.
and Use) Regulations 1994. PILOT BURNER’ can be ignored.

For Health and Safety information see back page. WARNING

Before the start of any servicing work, switch off at the
Electrical installation and servicing should be carried out by external electricity supply by disconnecting the supply plug
a competent person in accordance with the I.E.E. Wiring at the socket or switching off the external isolating switch.
Regulations. Turn off the gas service cock.
NOTE: After completing any servicing or replacement of
Servicing is best arranged by a contract placed with components check for gas soundness and carry out
Potterton Myson Limited and further details are available functional checks.
from Service Enquires - see back page.
1. PREPARING THE BOILER FOR SERVICING
The boiler DATA PLATE and WIRING DIAGRAM are See FIG. 14.
attached to the inside of the controls cover. The boiler CODE NOTE: Boilers with side or rear flues have a flue elbow
NUMBER which should be quoted when ordering spares or fitted to the fluehood.
requesting information is on the front of the control box. See The elbow is replaced by an adapter on vertically flued
FIG. 2. boilers.

All parts likely to require servicing are readily accessible. By A. Remove controls cover by opening the door
removing the cover from the boiler controls and removing the covering the securing screw on the underside of the
front door from the boiler, most components are exposed. controls cover, see FIG. 14. Undo securing screw,
Remove the front of the combustion chamber to gain access pull controls cover forward 10mm, lower it to release
to the main and pilot burner and the ignition electrode. it from its four side fixings and pull forward clear of
Removal of the fan and its mounting plate exposes the flue the thermostat knob.
system, i.e. the flue elbow and fluehood. These must be
removed to gain access to the flueways in the heat B. Remove door by undoing the lower fixing screws
exchanger for cleaning. and lift door off the two upper hinge brackets.

The following notes apply to the boiler and its controls but it
should be remembered that attention must also be paid to
the heating circuit itself including radiator

FIG. 29 BURNER AND GAS CONTROL ASSEMBLY

SERVICING INSTRUCTIONS - Page 22
C. Remove screws securing the combustion chamber front Remove the pilot injector and clean its orifice or replace.
panel and remove panel.
NOTE: Do not use a wire brush or pin to clean injector.
D. Disconnect the fan supply leads from the connector
adjacent to the fan. D. Gently clean any deposits from the electrode.

E. Remove the screws securing the fan mounting plate E. Refit the pilot injector to the pilot burner and assemble the
leaving in place the three screws identified with a red pilot to the aluminium tube.
circle or adjacent ‘F’ mark in fan plate.
Remove mounting plate complete with fan. F. Secure the pilot assembly to the main burner using two
hexagonal screws.
F. Disconnect the two flexible tubes from the flue elbow or
adapter. G. Fully tighten the union nut connecting the aluminium tube
to the pilot. Check for gas soundness at this joint by
G. Loosen the two brass securing nuts beneath the flue following the procedure described in the commissioning
elbow outlet and remove the other two. Tilt the flange and section of these instructions, Page 18.
withdraw the elbow. Take care not to damage the gasket.
On vertically flued boilers remove the four brass nuts and H. Ensure that the spark gap is as illustrated in FIG.30
slide the vertical flue adapter up into the flue duct.
H. Unscrew the four nuts and lift off the fluehood taking care
not to damage the rope seal.
Lower and lift out vertical flue adapter.

I. Undo the union on the gas service cock outlet.

J. Unplug the electrical supply leads for the gas control valve
from the control box. See FIG. 29.

K. Remove the screw securing the gas control valve to its

support bracket. See FIG. 29.

L. Disconnect electrode lead from electrode.

M. Remove two screws securing the burner assembly to the

bottom of the boiler case and lift out the burner and gas
control assembly
FIG. 30 PILOT BURNER SPARK GAP TOLERANCES
2. HEAT EXCHANGER
PILOT FILTER
A. Working from above and below the heat exchanger use a The pilot burner is protected from blockage by a pilot filter
suitable brush and remove all deposits from between the situated within the gas control valve. The filter is large and
fins. designed to last the life of the gas control valve under normal
Slide vertical flue adapter into flue duct. operating conditions it is therefore unlikely to need replacing.
However in the event of pilot filter blockage being suspected
B. Refit the fluehood, ensuring that the rope seal is the complete control valve should be replaced.
undamaged and that a GOOD SEAL is made with the heat
exchanger. Fully tighten the four nuts. 4. COMBUSTION CHAMBER INSULATION

C. Slide the flue elbow into the flue duct or lower flue adapter A. Check the combustion chamber insulation for damage. If
and secure to the fluehood using four nuts. Ensure that damaged replace as described under replacement.
the gasket between the fluehood and elbow or adapter is
undamaged and a good seal is obtained. 5. MAIN BURNER

D. Reconnect flexible tubes to elbow or adapter. A. Lightly brush any deposits from the top of each blade and
NOTE: Red tube connects the front aluminium tube in the ensure there is no fluff in the entry of the burner venturi. If
upper chamber to the lower connection on elbow or on re-assembly the burner flame picture is incorrect or the
adapter each being identified with a red ring. correct gas rate or burner pressure cannot be obtained,
remove the burner and gas control assembly and
3. PILOT BURNER thoroughly clean the burner. Clean or replace the injector.
In the event of the above procedures not rectifying the
The following operations are only necessary if the pilot flame is flame appearance, disconnect the burner from the gas
distorted or the wrong size, i.e. too small. control valve at the flanged connection and replace the
burner and injector.
A. Unscrew the aluminium pilot tube from the pilot assembly.
Take care not to damage the electrode. B. Refit the burner and gas control valve assembly into the
boiler, ensuring that the locating pin on the rear of burner
B. Unscrew the two hexagonal head screws secur-ing the engages correctly into the rear support bracket. Make sure
pilot (and shield on 80e) to the main burner and remove that the sealing gasket is in place and undamaged
the pilot assembly, be careful that the pilot injector does between the burner flange and the case. Secure the
not fall out during this operation. assembly with two screws.

C. Lightly brush the pilot and its shield to remove any

deposits.
SERVICING INSTRUCTIONS - Page 23
C. Refit the screw securing the gas control valve to the NOTE: A spacer is used between the valve outlet and the
support bracket. burner flange, requiring the use of two seals at this point. See
FIG. 26.
D. Reconnect electrode lead to electrode.
7. Use new seals on reassembly.
E. Plug gas control valve supply leads into control box.
8. Replacement is the reverse of removal.
F. Reconnect gas supply at gas service cock and turn on
gas. 9. Follow the full commissioning procedure as detailed in the
COMMISSIONING section of these instructions. Page 18.
G. Refit the combustion chamber front panel.
FAN
6. FAN 1. Switch off the external electricity supply by disconnecting the
A. Carefully clean any deposits from around the fan motor plug at the socket or switching off the external isolating switch.
and its supports.
2. Remove controls cover and case door as described in 1.
B. Very gently clean the fan impellor taking care not to ‘Preparing the Boiler for Servicing’, operations A and B.
damage the aluminium impellor or dislodge its balance
weights. 3. Disconnect the fan supply leads from the connnector adjacent
to the fan.
C. Replace the fan and its mounting plate. Ensure that the
securing screws are fully tightened as an air tight seal 4. Remove the screws securing the fan to the mounting plate and
must be obtained between the fan assembly and the main remove fan.
boiler casing.
5. Replacement is the reverse of removal.
D. Reconnect the fan supply leads (polarity is not important).
6. Following the full commissioning procedure as detailed in the
7. CASE SEAL COMMISSIONING section of these instructions. Page 18.
Check the case door seal. Replace if damaged. The seal is
simply pressed into the channel around the door. MAIN BURNER
1. Switch off the external electricity supply by disconnecting the
8. RECOMMISSION plug at the socket or switching off the external isolating switch.
Follow the full commissioning procedure as detailed in the
COMMISSIONING section of these instructions page 18. 2. Remove controls cover, case door and combustion chamber
front panel as described in 1 .‘Preparing the Boiler for
9. OTHER BOILER MOUNTED UNITS Servicing’, operations A, B and C.
No further servicing is required on any other boiler mounted
units. Repair is by replacement. 3. Remove the burner and gas control assembly as described in 1
.‘Preparing the Boiler for Servicing’, operations I, J, K, L and M.
10. FAULT FINDING
Refer to Fault Finding Chart FIG. 31 and Wiring Diagram 4. Unscrew the union nuts connecting the pilot supply pipe to the
FIGS. 27, 28. pilot and gas control valve. Take care not to damage the
electrode and be careful that the pilot injector does not fall out
REMOVAL/REPLACEMENT OF BOILER during this operation.
MOUNTED UNITS
Remove sealing grommet and withdraw the pilot tube through
GAS CONTROL VALVE the hole in the burner mounting flange.
This operation is most easily carried out by first removing the burner
and gas control valve assembly as follows:— 5. Separate the burner from the gas control valve at the flanged
connection by removing the four securing screws.
1. Switch off the external electricity supply by disconnecting the
plug at the socket or switching off the external isolating switch. NOTE: A spacer is used between the valve outlet and the
burner flange, requiring the use of two seals at this point. See
2. Remove controls cover, case door and combustion chamber FIG. 26.
front panel as described in 1. ‘Preparing the Boiler for
Servicing’, operations A, B and C. 6. Unscrew the pilot, main burner injector and pressure test nipple
from the burner.
3. Remove the burner and gas control assembly as described in
1. ‘Preparing the Boiler for Servicing’, operations I, J, K, L and 7. Use new sealing gaskets on reassembly.
M.
8. Replacement is the reverse of removal.
4. Disconnect the electrical supply wires from the gas control
valve noting their position. Refer to FIGS. 27, 28. 9. Follow the full commissioning procedure as detailed in the
COMMISSIONING section of these instructions. Page 18.
5. Unscrew the union connecting the pilot supply pipe to the gas
control valve. PILOT/IGNITION ELECTRODE
1. Switch off the external electricity supply by disconnecting the
6. Separate the gas control valve from the flanges at the inlet and plug at the socket or switching off the external isolating switch.
outlet ports by removing the securing screws.
2. Remove controls cover, case door and combustion
SERVICING INSTRUCTIONS - Page 24
chamber front panel as described in 1 .‘Preparing the Boiler for white wire from terminal C (3) of the control thermostat
Servicing’, operations A, B and C.
white wire from terminal NC (2) of the control thermostat
3. Disconnect the electrode lead from electrode.
brown wire from overheat thermostat
4. Unscrew the aluminium pilot tube from the pilot assembly.
Take care not to damage the electrode. blue wire from boiler terminal block connection N

5. Unscrew the two hexagonal head screws securing the pilot green/yellow wire from earth post
(and shield on 80e) to the main burner and remove the pilot
assembly, be careful that the pilot injector does not fall out 5. Release the control by lifting it from the four retaining lugs.
during this operation.
6. Remove electronic control.
Unscrew electrode retaining nut and withdraw the electrode.
7. Replacement is the reverse of removal.
6. Replacement is the reverse of removal. On re-assembly
ensure that the spark gap is as illustrated in FIG. 30. 8. Follow the full commissioning procedure as detailed in the
COMMISSIONING section of these instruc-tions. Page 18.
7. Follow the full commissioning procedure as detailed in the
COMMISSIONING section of these instruction. Page 18. PRESSURE SWITCH

COMBUSTION CHAMBER INSULATION 4. Remove the screw securing the pressure switch to the bracket
in the control box. Lift pressure switch from bracket.
1. Switch off the external electricity supply by disconnecting the
plug at the socket or switching off the external isolating switch. 5. Disconnect the two plastic tubes. NOTE: the red tube is
connected to the pressure switch connection identified with a
2. Remove main burner as described in ‘Preparing the Boiler for red ring, or adjacent red spot.
Servicing’, operations A, B, C, I, J, K, L, M.
6. Disconnect the three electrical leads, white wire from terminal
3. Bend back retaining tabs and replace insulation. It is necessary No. 1, or NC orange from terminal No. 2 or NO and brown from
to first remove the side insulation when replacing the rear. terminal No. 3 or C. Refer to FIGS 27, 28.

4. Replacement is the reverse of removal. 7. Replacement is the reverse of removal. Ensure that the plastic
tubes are not kinked on re-assembly.
5. Follow the full commissioning procedure as detailed in the
COMMISSIONING section of these instructions. Page 18. 8. Follow the full commissioning procedure as detailed in the
COMMISSIONING section of these instructions. Page 18.
FUSE, ELECTRONIC CONTROL, PRESSURE SWITCH, BOILER
THERMOSTAT, OVERHEAT THERMOSTAT, GRAVITY HOT OVERHEAT THERMOSTAT
WATER/PUMP OVERRUN THERMOSTAT
4. Remove door by undoing the two lower fixing screws and lifting
The following initial operations 1-3 are necessary to remove and door off the two upper hinge brackets.
replace any of the above items.
5. Disconnect the two push on electrical connections from the
1. Switch off the external electricity supply by discon-necting the overheat thermostat terminals.
plug at the socket or switching off the external isolating switch.
6. Remove the nut securing the overheat thermostat to its
2. Remove controls cover by opening the door covering the mounting bracket.
securing screw on the underside of the controls cover see
FIG. 14. Undo securing screw, pull controls cover forward 7. Noting the route taken by the capillary, loosen the plastic screw
10mm, lower it to release it from its four side fixings and pull retaining the thermostat bulb and withdraw bulb from its
forward clear of the thermostat knob. pocket. Remove the split grommet in the base of the boiler,
feed the thermostat capillary and bulb through the hole.
3. Remove control box securing screw and lower control box.
8. Replacement is the reverse of removal. Ensure the rubber
FUSE 1 amp grommet in the base of the boiler makes a good seal around
the capillary. Ensure that the capillary is secure in the clips
4. The fuse is located on the electronic control and can be provided. Refer to FIG. 21.
replaced by lifting it from its holder.
9. Follow the full commissioning procedure as detailed in the
5. Replacement is the reverse of removal. Refer to FIGS. 27, 28. COMMISSIONING section of these instructions. Page 18.

ELECTRONIC CONTROL BOILER THERMOSTAT

4. Disconnect six way plug, two way plug and electrode lead from 4. Remove door by undoing the two lower fixing screws and lifting
the electronic control. Refer to FIGS. 27, 28. door off the two upper hinge brackets.

Disconnect the flying leads of the electronic control as 5. Disconnect the fan supply leads from the connector adjacent to
follows:— the fan.

6. Remove the screws securing the fan mounting

SERVICING INSTRUCTIONS - Page 25
plate, leaving in place the three screws circled red, and remove GRAVITY HOT WATER/PUMP OVER-RUN THERMOSTAT. Refer
the plate complete with fan. to FIG. 2.

7. Disconnect the electrical connections as follows:— 4. Remove door by undoing the lower fixing screws and lifting
door off the two upper hinge brackets.
White from terminal C(3). White from NC(2)
5. Disconnect the electrical connections as follows:—
Refer to FIGS. 27, 28.
2 red wires from terminal NO(4)
8. Pull off the outer thermostat knob.
2 brown wires from terminal NC (2)
9. Remove inner thermostat post by undoing the two securing
screws. 1 white and 1 blue wire from terminal C (3)

10. Remove the nut securing the thermostat to the control box. 6. Remove the screws securing the thermostat to the control box.

11. If the boiler is fitted with a left hand flue, remove the flue elbow 7. Remove the split pin retaining the thermostat bulb in the pocket
as described in Section 1 Preparing the Boiler operations F, G, and withdraw the bulb.
page 22.
8. Remove the split grommet in the base of the boiler. Feed the
12. Remove the clip securing the thermostat bulb to the flow pipe. capillary and bulb through the hole.

13. Remove the split grommet in the base of the boiler and the split 9. Replacement is the reverse of removal. The bulb of the new
grommet in the fan chamber. Feed the capillary and bulb thermostat should be coated with heat conducting paste.
through the holes. Ensure the rubber grommet makes a good seal around the
capillary.
14. Replacement is the reverse of removal. The bulb of the new
thermostat should be coated with heat conducting paste. 10. Ensure that the capillary is secure in the clips provided. Follow
Ensure the rubber grommets in the base of the boiler and the the full commissioning procedure as detailed in the
fan chamber make a good seal around the capillary. COMMISSIONING section of these instructions. Page 18.

15. Ensure that the capillary is secure in the clips provided.

Follow the full commissioning procedure as detailed in the

COMMISSIONING section of these instructions. Page 18.
SERVICING INSTRUCTIONS - Page 26

FIG. 31 FAULT FINDING CHART

Publication No. 559880/0497

SHORT PARTS LIST - Page 27
P.I.L. G.C.
KEY No. Part No. Part No.

1 Pilot and Electrode Assembly including items 2-4 212259 382453

2 Pilot Injector 402915 381656
3 Shear Off Union 402492 357932
4 Electrode 402925 382448
6 Electrode Lead 407697 337369
7 Control Thermostat K36 L1014 907729 248147
8 Gas Control Valve Honeywell
— ) 907704 395796
9 Gas Control Valve White Rodgers) supplied as replacement kits including item 10
— 907702 382988
10 Gas Manifold Gasket 212105 337480
11 Gas Manifold ‘0’ Ring 401637 337467
12 Gravity DHW/Pump Over-Run Thermostat CL8 P1501 404501 337431
13 Flue Elbow Sealing Gasket 212084 337424
14 Electronic Control 407677 382462
15 Fuse (1 amp) 641903 336585
16 Thermostat Knob 225251 338445
17 Pressure Switch Beck
— 642208 381691
17a Pressure Switch Honeywell
— 642223
18 Fan 80e Boilers 409569 382445
30e, 40e, 50e and 60e Boilers 409583
19 Overheat Thermostat LM7 P8503 404495 382455
20 Main Burner Gasket 212085 337371
21 2.9mm Main Burner Injector 30e Boiler 410965 337374
3.1 mm Main Burner Injector 40e Boiler 410966 337375
3.5mm Main Burner Injector SQe Boiler 410967 337376
3.8mm Main Burner Injector 60e Boiler 410968 337377
4.4mm Main Burner injector 80e Boiler 410969 337378
22 Flue Brush (optional extra) 212154 337372
HEALTH AND SAFETY INFORMATION FOR THE
INSTALLER AND SERVICE ENGINEER - Page 28

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.

The following substances are also present.

Insulation & Seals

Material — Ceramic Fibre;
Alumino — Silicone 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.
Irritation to respiratory tract.

Precautions — 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
discomfort, follow good hygiene practices, wash
hands before consuming food, drinking or using the
toilet.

First Aid — Medical attention must be sought following eye

contact or prolonged reddening of the skin.

Thermostat

Material — Contains very small quantity of xylene.

Description — Sealed phial and capillary containing liquid.

Known Hazards Irritating to skin, eyes and throat.

Vapour is harmful.
Inflammable — do not extinguish with water.

Precautions — Do not incinerate.

Avoid contact with broken/leaking phials. Do not
purposely puncture.

First Aid — Eye/skin contact, wash with clean water, seek

medical attention.

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