PrimaF 30F, 40F, 100F, %0F, 60F Installation And Servicing Instructions

Supplied By www.heating spares.co Tel. [phone]

·

·~

~

POTTERTON

30F, 40F, 50F, 60F,

balanced

flue

THIS APPUANCE

gas

IS

FOR

USE WITH NATURAL

80F

& 1

fired

OOF

boilers

GAS

(G20)

ONLY

'

-

fanned

Installation

LEAVE THESE INSTRUCTIONS

and

Servicing

ADJACENT

Instructions

TO THE

GAS

METER.

Supplied By www.heating spares.co Tel. [phone]

CE

SAFETY, PERFORMANCE & QUALITY

Prima F boilers have been assessed

of

'Essential Requirements'
The Directive

construction, and use

and monitored system of quality assurance.

BSI kitemark remains

The

performance and

POTTERTON
POTTERTON
POTTERTON

lays

down

quality (BS.5750) standards.

PRIMA
PRIMA

PRIMA

30F G.C.
40F

SOF

the European

requirements for the safety and efficiency of the appliance, together with its design,

of materials. It also requires

on

the product. demonstrating continued conformity with

No.

41.607.01

G.C.

No.

41.607.02

G.C.

No.

41.607.03

CONTENTS

General

Optional Extras
Accessories
Installation Data
Boiler Dimensions
Site Requirements
Technical Data

Installation Instructions
Commissioning
Health and Safety Information
Control
Wiring Guide

User's Instructions

Systems, Pipework and

Literature

by

a Government appointed Notified Body and

Gas

Appliance Directive.

the

production process to

POTTERTON
POTTERTON
POTTERTON

PRIMA
PRIMA
PRIMA

IMPORTANT

Page No. 2
Page No. 2

Page No. 3
Page No. 3
Page No. 3
Page No. 3

Page No. 6
Page No. 11
Page No.

Back Page

Supplied

18

in

Pack

The appliance
competent
(Installation and Use) Regulations 1984.

Prima F boilers (formerly
are certified

that no

economisers,
appliances
instructions

Any
approved
certificate and

external control devices (e.g. flue dampers,

direct

must

person

by

BSI

etc.)
unless
or

otherwise

connection

by

Potterton

the

normal warranty.

shown

be

covered

the

relevant BSI safety,

60F

G.C.

80F

G.C.

100F

G.C.

be

installed

as

stated

known

for

safety. it is therefore important

be

directly

covered

recommended

of a control

could

to

meet the

by

an approved

No.

41.607.04

No.

41.607.32

No.

41.607.33

and

serviced

in

the

Gas

as 'Profile Prima')

connected

by

these

invalidate

installation

in

device

to

the

by

a

Safety

these

writing.

not

BSI

GENERAL

Prima F boilers are fully automatically controlled, wall
mounted.
using a cast iron heat exchanger and are available in

outputs

six
100,000 Btulh).
The boilers which are designed
hot

INDIRECT FULL y PUMPED systems only, which may

be sealed

The boilers can
types of

Standard
for a

fan

powered,

ranging

water

and/or

or

flue system:

horizontal

wall thickness of 100mm {4in) to 510 (20in).

central

open vented.

be

supplied with either of the following

balanced

from

heating

flue

flue

5.86-29.3

to

provide domestic

must

system

appliances,

kW

be

which

(20,000-

is

used

suitable

on

PRIMA 100F MODEL ONLY
1

metre

maximum flue length of 955mm (37in).
Vertical

through a

980mm (38in) measured from the top

of

PRIMA 30F, 40F, 50F, 60F & 80F Models only
2

metre

maximum
Vertical

through a flat roof and terminate

1980mm (78in) measured from the top of boiler case.

of

OPTIONAL EXTRAS

The following are kits available as optional
lnternal Fitment Kit, which is suitable for a maximum

wall thickness of 510mm (20 in.) is

to

access
Pump

designed
valves installed above the boiler.
be fitted above

used).
Terminal

to the outside
after making good around the

the outside wall is impracticable.

Cover

Kits

located

to

conceal the pump, and/or any motorised

the

wan

Plate, where necessary can

wall face to improve the appearance.

boiler

on

if

to

top

(Note:

the

vertical

terminal.

extras:-

be used where

of

the

boiler

Pump cannot

flue

be

and

kit

fitted

is

Terminal

fitted less
above a flat roof

45°
flexibility (Prima

Vertex
flexibility
only).

Full
SEE PAGE

OPTIONS.

2

horizontal

Flue

system

flat roof and terminate at a maximum height

horizontal

flue length

flue

system

Guard,

than

and

90°

Flue

through

fitting instructions are provided with each kit.

10

flue

system

which allows

flue

system

of

1955mm (77in).
which allows

to

be

used

2m

above a balcony, above ground

to

which people have access.

Flue

Bend

Kits,

30F

to 60F only).

Kit,

giving

a roof

FOR PART Nos. OF FLUE KITS AND

space

which

which

at

a maximum height

when

giving greater flueing

greater

(Prima

provides

the

flue

of

boiler case.

provides

the

flue

the

vertical

to

to

terminal

30F

pass

pass

flueing

to

a

a

is

or

60F

Supplied By www.heating spares.co Tel. [phone]

ACCESSORIES

The following Potterton Myson controls are

recommended
Electronic Programmer EP2001,
Cylinder Thermostat PTT2
Room Thermostat PRT2

for

use with your boiler:-

or

PTI100

or

PRT100

EP300i.

or

EP6000

Frost Thermostat PRT100 FR

INSTALLATION

The installation
with

the

latest

Safety

{Installation and

building regulations, IEE Wiring Regulations and the

Byelaws

of

Detailed recommendations are

following British Standards and Codes of Practice.

BS6798, BS5440 Part1

of

the boiler must be

relevant

requirements

Use)

the

Local Water Undertaking.

in

accordance
of

the

Gas

Regulations, local

contained

in the

BOILER

RETURN

Motorised

Zone Valve MSV222
Motorised Diverter Valve MSV322
Thermostatic Radiator Valve

Data Sheets describing these products are available
on

request.

DATA

BS5440 Part 2 BS5449 Part1

BS5546 BS4814. BS6891.
BUILDING REGULATIONS.
MODEL

BRITISH

GAS

WATER BYELAWS.

GAS

SAFETY

REGULATIONS.

BUILDING STANDARDS (SCOTLAND)
REGULATIONS.

DIMENSIONS

or

MSV228

PUBLICATION DM2.

(INSTALLATION

·so

(60)

AND

USE)

srr

srr

FIG. 1

Boiler

Dimension 'A'

(mm)

Flow/Retum

Connections

'B'

'C'

'D'

30F

350
110
103

87 87

22mm

Copper

These boilers are not suitable for external installation
and should not

appliance. The boiler may
although particular attention is drawn
ments of

the

current
Scotland, the electrical provisions of the Building
Standards applicable in Scotland with respect to

40F

350 350

110
103

22mm

Copper

Copper

50F

110

103

87

22mm

60F

3SO

110
103
107

22mm

Copper

80F

425

150
143

107

28mm

Copper

SITE

be

fitted directly above a cooking

be

installed in any room,

to

the require-

l.E.E.

Wiring Regulations and

100F

425

150

143
107

28mm

Copper

REQUIREMENTS

installation
or

Where a room-sealed appliance is installed in a room

in

the

containing a bath or shower, any electrical switch or

appliance control, utilising mains electricity should
situated that it cannot
bath or shower.

3

600

I

1HE

100

I

BOltER

is

inverted).

*30

(40)

(40)

•NOTE:

IF

PIPEWORK
NORMAL CLEARANCE OF
ANDWALLCANBEINCREASEOT035mmlFDESIREDBYIN\/ERTINGTHE
BOILER MOUNTING

(Dimensions in

IS

TO BE RUN DOWN

25mm

PLATE DURING INSTAUATlON

brackets

apply

of

the appliance in a room containing a bath

THE

BACK OF

BElWEEN THE REAR OF THE BOILER

when the mounting plate

shower.

be

touched

by

a person using the

be

THE

so

Supplied By www.heating spares.co Tel. [phone]

FLOW

PIPE

RETURN PIPE

CONTROL

THERMOSTAT

PUMP OVER-RUN

THERMOSTAT

THERMOSTAT

CAPILLARY

RETAINING CLIP

~

/

FLUE
ELBOW

FAN

SUPPLY

LEADS

CONNECTOR

FAN

FLUE

HOOD

HEAT
EXCHANGER

OVERHEAT
THERMOSTAT
POCKET

BOILER DRAIN

CAP

ELECTRODE~

PILOT

GAS

COCK

COMBUSTION
CHAMBER

AIR

DEFLECTOR

CHANNEL

MAIN

BURNER

PUMP
OVER-RUN

THERMOSTAT

CONTROL

BOX

GAS
VALVE

CONTROL

FIG. 2 GENERAL

BURNER

TEST

POINT

PRESSURE

ARRANGEMENT

4

\

OVERHEAT
THERMOSTAT

CODE

CONTROL
THERMOSTAT

BADGE

Supplied By www.heating spares.co Tel. [phone]

Where

location, special
6798 gives detailed guidance

Ensure that the

enough for

the installation of the boiler will

procedures

gas

this

appliance

supply

may

on

pipe

and

be

this aspect.

and

any
run off the same meter. Reference
BS6891

Boiler
The boiler

of
to
local authorities

Mounting

must

combustible

take the

weight

Surface

be

mounted

material and

of

the boiler.

and

on

a flat wall,

must

The

the Building Regulations

be

adhered to.

IMPORTANT
TIMBER

If

the appliance is
it should
Publication

Framed Housing'.
from the local

Clearances

NOTICE:

FRAMED

to

be

fitted in

DM2

'Guide for Gas Installations in

Gas

Around

HOUSES
be

fitted in a timber framed building,

accordance

If

in doubt,

Region

the

advice

of

British Gas.

Boiler

The following minimum clearances

after installation, for correct operation
the boiler:

61

Omm (2 ft) at the front

Smm (0.2 in) each side

of

the boiler

of

the boiler

be

in an unusual

necessary

and

meter are large
others that
should

be

which

may

made

may

sufficiently

requirements

must

with

British Gas

must

be

must

be

maintained

and

servicing

BS

be

to

be

robust

of

the

be

Timber

sought

of

50mm

boiler case),

cover

(2 in)

is

to

at

the

except

be

fitted,

top

(measured from

where

when

the
178mm

optional extra

allowed.
100mm
Additional

installation for lifting
required at the

(4 in) at the

clearances

top

bottom

the

of

of

to

these are required during

boiler

the boiler for

the boiler.

and

connections.

Ventilation

If

the boiler is
a cupboard, the
must

be provided

each

of
TABLE
a compartment are given in

to

be

installed in a confined

space

at

the

which

should have a free area

1. Further details

will

need

top

and

for

installation

BS

ventilating.

bottom

6798.

TABLE 1

PRIMA

30F

40F
50F
60F
80F 43 277

100F

AIR

VENT

2

in

16 103

21
26 170
32 206

54

If the openings draw air from outside

free

areas

may

be

halved. Refer

for further guidance.

the

top

(7 in) should

127mm

access

to

space

Openings

of

the

cupboard

as

shown

of

a boiler within

AREAS

2

cm

135

349

the

building the

to

BS

5440

of

pump

(5

in) is

the

such

Part 2

the

be

pipe

as

in

Balanced Flue Terminal

The fresh air inlet

left, right, rear

the
terminal

on

and

the outside

The minimum spacings from the

and ventilation openings are
mation appertaining

reference should

be

flue

or

top

made

and

Ducting

ducts

can

be

run

from either

of

the

boiler

to

a miniature

of

the building.

terminal

shown

to

horizontal flue lengths

to

FIG.

to

obstructions

in FIG. 3. For infor-

4.

INFORMATION RELATING
PROVIDED
CAL

NOTE
Where a flue terminal is fitted less than 1000mm from a

plastic
an
underside of gutter

Any

If a terminal is fitted less than 2m above a balcony,

ground

then a suitable terminal

or

above a flat roof

to

which

guard

people

should

be

have

fitted.

above

access

(P.l.L

a roof

and
suspect and further

No. 205792).
Ref

er

to BS5440 Part 1

Under

Carport.

FIG. 3

THE

for

further

--~-~~-~~-·---!"--.+-

SITING

FLUE

TERMINALS

guidance.

'fo

1--"-o..£.

L~

OF

BALANCED

/

!G

POSITION MINIMUM DISTANCE

A. DIRECTLY BELOW

B.

C. BELOW EAVES

0. BELOW A

E FROM VERTICAL DRAIN PIPES ANO

/

F.

G.

H.

I.

J.

K.

L HORIZONTALLY FROM A TERMINAL ON

M.

5

TO

VERTICAL FLUING IS

IN

THE PACK CONTAINING THE VERTI-

FLUE SYSTEM.

or

painted gutter

aluminium shield

car

port

or

other

or

a roof

and

two

other walls - the installation shall

WINDOW,

VENTILATION OPENING.
BELOW

SOIL
FROM
ABOVE ADJACENT GROUND OR BALCONY

LEVEL
FROM A SURFACE FACING THE TERMINAL
FACING TERMINALS

FROM

CARPORT INTO DWELLING

VERTICALLY FROM A TERMINAL

THE SAME

THE SAME WALL

ADJACENT

AIR VENT,

GUTIER.

BALCONY

PIPES

INiERNAL

OPENING

WALL

TO

OPENING

or

500mm from painted eaves,

of

1000mm length

or

eaves.

add-on

one

advice

AN

OR

DRAIN/SOIL

OR

OR

(DOOR/WINDOW)

extension should consist

other wall. If it consists

sought.

OPENABlE

ANY

OlHER

PIPE

CAR PORT ROOF

EXlERNAL

CORNERS

IN

ON

should

be

be

fitted

of

a roof

treated

1.200

1.200

1.500

to

of

as

300

25
25
25

75

25

300
600

300

150

Supplied By www.heating spares.co Tel. [phone]

REAR OR SIDE FLUEING

MAXIMUM

LENGTH'X'

=

FIG. 4 FLUE LENGTHS

ELECTRICITY
A 240

fused
with
and

voHs-

to

the

any

current rating

3 amperes and have a cross sectional area

0.75mm2
The

supply to the boiler and its associated equipment

SUPPLY

50Hz, single

3 amperes, must

latest edition

other

local regulations

of

the wiring to the boiler must exceed

in

accordance with BS 6500. Table 16.

of

the

phase

be

provided

1.E.E.

electricity

in

Wiring Regulations

that

may apply.

accordance

of

at

supply

The

least

STANDARD
SYSTEM

1

METRE
SYSTEM
100F

2METRE
SYSTEM

30f.

MODELS

should be controlled
pole switch {having
in

both

poles)

supply

can

be achieved

RULE

MODEL

FLUE

40F.

50F'

ONLY

so

that

FLUE

by

at

be carried out in safety.

GAS

SUPPLY

A

gas

supply pressure

inlet

to

the appliance. Performance

·use of reference

gas

ONLY

60F & 80F

an

least

complete

to

of

G20.

1955mm

exclusive

3mm

contact separation
isolatron

enable

20

mbar

s1omm

(2Qin)

955mm

(37in)

(nin)

3A

fused

from

servicing

work

is required at

data

is based

double

the

to

the

on

Maximum working head
Minimum working head
Gas supply pressure
Maximum flow temperature
Electricity supply

Internal Fuse
Power Consumption
Gas supply connection

Appliance lift weight (min)
Appliance weight

installed

Water content

Row/Return connections

TECHNICAL DATA

30.Sm (100ft)
150mm.(6in}

20mbar

82°C

240v-50Hz fused at 3A

TypeT1A

80

Watts (excluding pump)

Re. 1h (%in BSP female)

30F, 40F, 50F & 60F Models

26.0kg

37.1

2.0 litre (0.44 gal)

(57.31bs)

kg

(81.81bs)

22m copper

80F & 100F Models

33.Skg

46.4kg

(73.871bs)

(102.31bs)

2.4 litre (0.53 gal}

28mm

copper

6

Supplied By www.heating spares.co Tel. [phone]

I

I

BOILER

SIZE

INJECTOR

SIZE

GAS RATE

m%

(ft%)

INPUT

kW(Btu/h)

OUTPUT

kW(Btu/h)

BURNER

mbar

PRESSURE

iowg

i

l

30

l

40

150

100

60

80

Min
Max

Min

Max

Min

Max

Min

Max

Min

Max

Min

Max

2.9mm 0.87(30.61) 9.29(31686)

3.1mm

3.5mm

3.6mm 1.89(66.84) 20.28(69182)

4.4mm

4.7mm 3.10(109.38)

0.71

(25.23) 7.65(26116)

1.03(36.23) 10.99(37500)

1.06(37.40)

1.21

(42.86)

1.37(48.31)

1.39(49.11)

1.54(54.35)

1.71

(60.39) 18.32(62500)

1.73(61.07)

2.05(72.46) 21.98(75000)

2.13(75.19) 22.81(77821) 17.58(60000)

2.43(85.94)

2.74(96.62)

2.78(98.09) 29.75(101523) 23.45(80000)

3.42(120.77) 36.64(125000)

11.35(38710)

13.00(44360)

14.65(50000)

14.90(50826}

16.49(56250)

18.53(63211) 14.65(50000)

26.07(88945) 20.52(70000) 8.7

29.31(100000) 23.45(80000)

33.18(113208) 26.37(90000) 9.9 4.0

CIRCULATION PUMP SELECTION

The resistance through the heat exchanger when
operating with a water flow rate producing
temperature rise at maximum
TABLE

2.

If other controls, such as three-position valves

boiler output are shown in

an

11

° C

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
or

return and MUST be wired directly

terminal block,

isolating
pump as

see

FIG.

23. It must be fitted with two

valves which are positioned as close

possible. Closing of any valve must always

to

flow

the boiler

to

the

leave the open vent unobstructed.

5.86(20000)
.33(25000)

7

8.

79(30000) 8.4

8.79(30000)

10.26(35000)

11.72(40000)

11.72(40000)

13.19(45000)

14.65(50000)

16.12(55000)

17.58(60000)

29.3(100000)

TABLE2

Boiler size Water Flow

Litres/sec

30F

40F

50F
60F

80F

iOOF

.19
.25
.32 4.17 4.25
.36 5.0 6.25
.51 6.67
.64

3.9

5.9 2.4

6.5

8.6

11.3

7.0

8.6

11.0

10.7

12.8

14.9

6.6 2.6

11.8 4.7

8.0

12.2 4.9

Rate

gal.min

2.5 1.5

3.34

6.4

BOILER

RESISTANCE

2

kN/m

3.0

7.0

11.0

1.6

3.4

2.6

3.5

4.5

2.8

3.5

4.4

4.3

5.1

6.0

3.5

3.2

inwg

6.0

12.0

17.0

25.0

28.0

44.0

kN/m2 in wg

12.0

Imp. Gall/min.

Litres/sec

46

·---r--··~·~--~·-~--~·~-~--~-~-r~

1 2 3 4 5 6

.76 .152 .227 .303 .379 .455

.53

BOF

& 100F

7

.61

8

9

.68

FIG. 5 PRESSURE LOSS ACROSS BOILER

7

Supplied By www.heating spares.co Tel. [phone]

The System

The

boiler

must

be

used

on

INDIRECT FULLY PUMPED

systems

The

static
minimum

On
tenninal block, it will
over-run thermostat.
continue
temperature b !1igh,
of

It is

valves are
when

with
heating
with a

within
If a three port divertervalve

a
open.

Where a
necessary. The total length
from

metres
lockshield

flow

FIGS
Systems fitted with

· operate
circuits are closed i.e.

static control valves,
capable of:-

1. Dissipating a

2.

A suggested

using a bathroom radiator fitted

valves

Additional system information
Control Systems, Pipework

Drain off
the

only,

which

system

head

should

does

of 150mm (6in).

all

systems

the

overheat thermostat.

important

the

controls

circuits

by-pass

the

by-pass

the

through

6.

7.

Maintaining a

boiler

is

boiler

the

to

run after

that

used

the

zone valves are closed. Also, systems

that

while

circuit

boiler.

is

not necessary since

pair

of

two

boiler

connections

of

22mm pipe. It

valve and

the

when

both

minimum

of

9 litres/min (2 gal/min).

method

shown

taps

and

in

should

in

may

be

designed

not

exceed

pump

then

This

boiler

thus

preventing nuisance operation

where

boiler

close

the

to

dissipate

port

be

adjusted

boiler

of

controls
the

mechanically

must

minimum

of

meeting

FIGS. 6, 7.

be

the

low

be

sealed

See

FIG 6.

should

be

will

ensure

electrically operated

is

wired

both

boiler

is

used

valves are used, a

of

the

should

should

4.5

litres/min

which

hot

water

be

fitted

of 1 kW

water

and

fitted

points

NOTE

Although
taps
empty
cap

the

system

installed

the

boiler

positioned

in

the

it

within

can

be

pipework

is

necessary

the

emptied

boiler

or

open

vented.

so

that

the

maximum

30.5m (100ft) and a

be

wired

to

the

controlled
shut

hot

is

still hot,
the

as

one

by-pass

to

with a by-pass

these

can

Wiring Guide.

in

the

of

around

to

case. See FIG. 2.

by

the

that

the

pump

down

if

the

so

it

does

not

water

and

must

residual heat

shown

be

maintain a

allow

and

(3400 Btu/h).

with

the

remove

in

FIGS. 6, 7

circuit

be

operated

flow

be

pipework

using

is

by-pass

circuit
greater
fitted with a

minimum

(1

gal/min)

the

central

through

requirements

two

lockshield

found

system.

the

the

system,

the

central.

be

always

than

boiler

heating

thermo-

close

drain

drain

boiler

pump

will

water

zone

cycle

fitted
fitted

from

taken

see

circuit

the

by

in

the

is

4

to

to

off

to

off

SEALED SYSTEMS

Installation

The installation

BS 6798 1987

"British Gas Specification

Heating

Systems"

must

and

comply

BS

5449

should

with the requirements

Part

1.

The B.G.

for

also

Domestic

be

consulted.

Wet

publication

Central

Safety Valve

A non-adjustable spring-loaded safety valve, preset

operate at 3
with

BS

It shall

or

vertically
valves are
valve. The valve
which

such
components

bar

(451bf/in

6759 Part 1 and

be

positioned

upwards

to

be

placed

should

permits

that

no

the

hazard

is

caused.

in

and

safe

to

2

shall

be

)

include

the

between

be

discharge

persons

a manual

flow

close

to

the

installed

used.

It

must

testing

pipe

either

honzontally

the

boiler.

No

boiler

and

into a discharge

of steam

or

damage

and

to

comply

device.

shut-off

the

safety

pipe

hot

water

electrical

Pressure Gauge

A pressure gauge incorporating a fi II

the

covering
system. It

the

same

at
should

be

range 0-4

should

point

visible from

bar

be

connected

as

the

the

(601bf

expansion vessel. Its location

filling point.

pressure

2

)

/in

shall

be

to

the

system, preferably

indicator,

fitted

to

Expansion Vessel

A diaphragm
shall

be

connecting

nominal). Pipework connecting
should

supporting
The nitrogen
vessel shall

of

the
vessel). To size
to

calculate

The

following

guide

to

Boiler Heat Exchanger: 6.5 litres
Small Bore Pipework: 1 litre

Micro

Bore Pipework:

Steel Panel Radiators:

Low Water Capacity Radiators:

Hot

water Cylinder:

type

expansion vessel

fitted

close

to

the

inlet side

pipework

not

incoporate valves of any sort.

the

or

not

top

point

the

volumes

calculating

should

vessel are supplied

air

charge

be

less

of

the

the

expansion vessel it

volume

the

not

pressure

than

the

hydrostatic

system above

of

water in

may

be

system volume.

be

less

the

by

the

used

system
7 litres
8 litres
system

2 litres
system
2 litres

to

BS4814 Part 1

of

the

pump.

than

15mm (%in

expansion

Methods

the

manufacturer.

of

the

expansion

head

the

expansion

is

first necessary

system

as

a conservative

per

kW

output

per

kW

output

per

kW

output

vessel

(height

in litres.

of

of

of

of

to

the

The

of

8

Supplied By www.heating spares.co Tel. [phone]

If the system is extended, the expansion vessel volume

may have to
been made for the extension. Where a vessel
calculated size is not
size should

boiler flow temperature is controlled at approx-

The

imately
The vessel size can now be determined from the follow-

ing table where V=System volume in litres.

Vessel Charge Pressure(bar)

Initial System Pressure (bar)
Expansion Vessel Volum.e (litres)

be increased unless previous provision has

available, the next available larger

be used.

82°C.

0.5

1.0

v x 0.11 v

of

the

1.0

1.0

x0.087

Cylinder

The hot water cylinder must be

cylinder fitted with an immersion calorifier suitable

direct
for operating at a gauge pressure

excess of safety
cylinders are not suitable for sealed systems.

valve setting. Single feed indirect

an

indirect coil type

of

0.3

bar

(51bf/in

or

2

)

a

in

Method

Provision shall be made for replacing water loss from the
system
i)

ii) where access to a make-up vessel would be difficult

Mains

There shall be

or
water even through a non-return
approval

of

Make-Up

either.­from a make-up vessel
higher than the
ted through a non-return valve to
return side
all heat emitters.
or

by

using the mains

automatic pressurisation and make-up unit as
trated in FIG. 7 METHODS 1 and

top

of

hot water cylinder

or

tank mounted in a position

point

of

the system, and connec-

the

system

or

the return side

top

up

method

2.

or

a remote

on

Connection

no

connection to

to

the water storage tank which supplies domestic

of

the local Water Authority.

the

mains water supply

valve, without the

the

of

illus-

Filling Point

The system shall be fitted with a filling point at low level
which incorporates a stop
check valve (approved

be fitted in this order from the system mains, Refer to

FIG. 7. Method 1.

valve

to

BS 101 O and a double

by

the National Water Council) to

WATER
LEVEL

l--

TOP

OF

CASING

BOILER

I

BY-PASS
BALANCING

OPTIONAL
ZONE

OPTIONAL

3

PORT

·~---~--------<

I

VALVE

t

'

X-r

X-L

I
I

I

______

VALVES

~

~r

VALVE

~LJ

--.,

I

_j

ALTERNATIVE
ARRANGEMENT
BATHROOM
FITTED
VALVES

WITH

RADIATOR

XVENT

1 1

.-1...

1---1

..J

BY-PASS

USING

TWO

LOCKSHEILD

.---..

>--

t....

-

.J

THE

~

------------{.:>

FIG.

6 OPEN VENTED

Flrreo

WITH A COMBINED FEED AND VENT

FULLY

PUMPED SYSTEM

9

Supplied By www.heating spares.co Tel. [phone]

SAFETY
VALVE

A EXPANSION

u VESSEL

BOILER

PRESSURE
GAUGE

T---.

~

BY.PASS \

8AlANCINGVALVE

FILLING POINT

-----

OPTIONAL
ZONE VALVES

OPTIONAL~'

3PORTVALVE

~-~------~

' '

I I

X-L-

><VENT

~

~

~L

- J

,_,

L-J

<--J

·~\~~~---J.--~~

\

ALTERNATIVE BY-"ASS
ARRANGEMENT USING THE
BATHROOM RADIATOR
FITTED WITH
VALVES

CYLINDER

.__

·----c---------

TWO lOCKSHIELD

Y-KEUP

I VESSEL

I

I

I
I

--t>

Two methods

METHOD 1

MAINS TOPPING-UP
METHOD

NOTE:

This
system
to

the

method

may

only

Local

be

Water

Undertaking

HEATING
SYSTEM

'-='---+<lf-r-1KJ--------C><l-

of

filltng a

used

DOUBLE
CHECK

sealed

if

acceptable

VALVE

MAINS

WATER

SUPPLY

RV

ICE

!SE

VALVE HOSE

PIPE l

HOS(UNION

STOP TEMPORARY

FIG 7. FULLY PUMPED SEALED SYSTEM

FLUE KITS AND OPTIONS (See Page 2)

30F

Standard
1 metre

Flue

Flue

System

System

225540 225540 225540

NIA

2 metre Aue System 225543
Vertical

Flue

System 225157

40F

N/A

225543
225158 225159

of

filling a sealed

water system

j

SOF

NIA

225543

60F

225541

NIA

225544
225160

METHOD2

CISTERN FILLING METHOD

NOTE:

Cistern

to

be
temporary
pipe

or

cold

STOP VALVE

225541

225544

225161

connection

water

BOF

NIA

supplied

from

distributing

\

PRESSURE

REDUCING

llF

AEOVIREO)

100F

225542

225545

NIA

225162

a service

through

a

pipe

OVERFLOW]

CISTERN

;-

-t:><J--

PUMP

VALVE

STRAIGHT
FLUE
KITS

I

MAINS
WATER
SUPPLY

90"

Flue

Bend

45°

Flue

Flue

Elbow

(For

use with
Vertical
(For

use

1 metre

metre

2

Vertex

Flue

Vertex

Flue

Terminal
Terminal

Internal
Pump

Cover

Pump

Cover

Pump

Cover

Pump

Cover

Kit

Bend

Kit

Kit

Flue

Bends)

Flue

Terminal

with

Flue

Flue

System 225545

Flue

System 225544

Kit

Bends)

Kit
1 metre extension

Wall

Plate 212306

Guard 205792

Fitment

Kit

Kit

(Gin)

Kit

(7in

12in)

Kit

(13in

-18in) 225424

Kit

(19in -24in)

225600
225601

225602 225603

225606

225700

kit

84265

225183 225183
225422
225423

225425

225600

225600

225601 225601

225604

225607

225608

225545 225545
225544 225544

225701

84265

212306

225702

B4265

212306

205792 205792

225183
225422 225422
225423
225424

225423

225424
225425 225425

225600
225601

225605

225609
225545

225544

225703

84265

212280 212280
205792
225184
225422 225418
225423
225424

225425

10

NIA
NIA

NIA

NIA
NIA

NIA

NIA
NIA

205792
225184

225419

225420
225421

NIA
NIA

NIA

NIA
NIA

NIA

NIA
NIA

212280
205792
225184
225418
225419
225420
225421

FLUE
BEND
KITS

J_

VERTEX
FLUE KITS

OTHER

KITS

J_

Supplied By www.heating spares.co Tel. [phone]

INSTALLATION INSTRUCTIONS

It is the law that all gas appliances are installed and

serviced

Safety {Installation and Use) Regulations 1984.
For Health and Safety information see back page.
Electrical
competent
Wiring Regulations.
The boiler and its associated equipment will arrive

site in two cardboard cartons. The contents of each
carton is as follows.

CARTON 1
Boiler

Template

Literature Pack Containing:-

lnstallation and Servicing Instructions
User's Instructions
Control Systems Pipework and Wiring Guide

Auxiliary Pack Containing:-

Boiler Mounting Bracket
Gas

by

competent

testwork

person

:-

Boiler

Service Cock and Accessory Packs

SIDE

OF

REFERENCE

BOILER

persons

should

in

accordance

Pack

MARK

as stated in

be

carried

with

TOP

BOILER

out

the

OF

Gas

by

LE.E.

on

a

CARTON

Horizontal Flue Packs

Air/Flue Duct Assembly (length as ordered)
Flue Elbow Extension
Flue Terminal

Flue Sealing Collar
Rope Sealing Ring
Side Infill Panels-2 off

Vertical

Air/Flue Duct Assembly

Flue Terminal
Terminal
Vertical Flue

Accessory
Side Infill Panels-2

Flue

2:-

Flue

System

Flue Pack (2 cartons)

Cowl

Adaptor

Pack

Installation Instructions

Pack

off

HOLE WALL

FOR

'-....

A

D

0 '

FOLD

LINE

FOR

LH

FLUE

OUTLET

FIG.

8 TEMPLATE

Place template in proposed boiler position ensuring n
level (the minimum side clearances are automatically
allowed

REAR
Mark holes

boiler reference lines throught slots
SIDE FLUING

Mark hole positions 'A', 'D' and side
lines through

Mark large flue outlet hole and holes 'B' using the

thick lines on the template for minimum

the rear of
maximum

NOTE - Prima 30F, 40F

If
size
centrally

marking around the outside of the collar.

for)

FLUING

'A',

slots 'C'.

the

clearance. See note on Fig. 1.

a flue bend kit

is

obtained

over the marked flue outlet position, and

BOTTOM

'B', 'D', large flue outlet hole and side of

boiler and the

is

to be used. the correct flue hole

by

placing the

and

OF

50F

BOILER

thin

TEMPLATE

·c·.

of

boiler reference

clearance at

dotted lines for

only

wall

sealing collar

1s

SIDE

REF.MARK

SCREWS

FIG.
Remove template and carefully cut flue outlet

through wall. It necessary make good around hole to
enable holes 'B' to be drilled. (If internal flue fitment kit is

being used refer to instructions supplied with kit).
Drill holes 'A' using a 7 mm drill
Drill holes

Using wall plugs,
A)
level and the correct way up,

at
using the

Insert wall plugs into holes 'B' (accessory pack

hole 'D' (accessory pack
Insert flue sealing collar into wall and secure with screws

provided, (accessory pack
wall surface around flue sealing collar.

11

PLUG

FLUE

OUTLET

0

()

OF

BOILER

9 BOILER MOUNTING PLATE

attach boiler mounting plate to wall. Ensure that it
the rear of the boiler allowed for when marking out

-----

r;:::;.===~rT.e~---TOP

- - - -

C)

CUPWASHER

'B' and 'D' using a 5 mm drill

screws and washers {accessory pack

template. See also NOTE on

--

-a

.

L

-

0

i.e.

D).

B).

-~FIXING

REAR

"

to provide the clearance

Make good the internal

SEALING
COLLAR

FOR MIN.

CLEARANCE

FIG.

1.

SCREWS

hole

B)

and

is

Supplied By www.heating spares.co Tel. [phone]

FIG. 1

Oa

SIDE

i---

FLUE

·x·

-··~..;

I

CUTTING AIR/FLUE DUCTS

AG.

10b

REAR

FLUE

1. Measure from outside face
casing reference

2.

Take

air /flue duct assembly and measuring from the

flanged end, mark and cut the outer

flue duct to dimension 'x' plus 20mm. Ensure that

both ducts are cut squarely.

30F

to50F

FIG.

11

AIR/FLUE

line (dimension 'x').

TERMINAL

DUCT

of

wall to the side

INNER
DUCT

ASSEMBLY

duct

FLUE

of

and inner

boiler

1. Measure wall thickness (dimension 'Y').

2.

Take

air/flue duct assembly and measuring from

flanged end, mark and cut the outer air

flue duct to dimension
both ducts are cut squarely.

'Y', plus

duct

and inner

45

mm. Ensure that

NOTE

Cutting length remains the same for minimum or

maximum clearance at

AIR

DUCT

the rear of the boiler.

ROPE

SEALING

RINI'";

the

1.

Slide rope sealing ring on to air duct.

2.

Engage the terminal on

to

the ends

flue duct and press fully home.

FIG.

12

SECTIONAL
DUCT

ASSY THROUGH WALL

VIEW

OF

AIR/FLUE

of

the inner

3.

Engage four screws from accessory pack

the

pre-drilled holes in the terminal and screw fully

·c·

into

home.

These screws which are self drilling will pierce the
air duct and secure the terminal to air duct.
On models 30F
pilot holes in the air

4. Protect duct where it is likely to come into contact
with

mortar

(accessory pack E).

5.

Insert the assembly into
sealing ring along the air duct into the tlue sealing
collar.

Bend
inwards to retain the rope sealing ring. Ensure air
duct flange studs
onto mounting bracket.

to

50F, it is necessary to drill four

duct

by

using

the

adhesive

the

wall

six

tabs

on

flue

do

not obstruct lifting

tape

sliding the rope

sealing

provided

collar

of

boiler

12

Supplied By www.heating spares.co Tel. [phone]

FAN

FLUE OUTLET

SEALING

CONNECTOR

PLATE

DOOR

FIG.

13

PREPARING

COMBUSTION

CHAMBER FRONT
PANEL

THE

BOILER

BOILER

ASSEMBLY

MAIN

SECURING SCREW
ACCESS DOOR

The controls cover should have been removed

unpacking
opening the
underside

the

boiler,

door

of

controls cover, see

if

not remove controls cover

covering

the

securing screw

FIG

13.

when

on

the

by

Undo securing screw, pull controls cover forward 10 mm,

lower to release from four side fixings and

clear

of

thermostat knob.

Remove the

door

lift
Disconnect
Remove

remove

door

off

the

the

thumb

elbow

by

undoing

two

upper

two

flexible tubes from

the

lower fixing screws and

hinge brackets.

screw securing the flue

by

sliding forward

to

disengage

pull forward

the

flue elbow.

elbow

it

and

from its

rear retaining flange.

NOTE

The boiler

sealing plate removed.
required, remove
and transfer

is

supplied with the left hand flue outlet

If

another flue outlet direction

the

appropriate flue outlet sealing plate

it

to

the left hand position.

is

The boiler may now

if desired

the

by removing the fan/fluehood assembly also

be

lifted onto

its

appliance lift weight can

mounting bracket

be

further reduced

the

gas control assembly as follows.

1. Removing fan/fluehood assembly.
Disconnect

connector

the

fan

adjacent

supply

to

the

and earth leads from the

fan. Remove

the

two
nutssecuringthefluehoodtotheheatexchanger.Uft
out

fanlfluehood assembly.

2.

Removing burner/gas control assembly.
Remove

chamber
electrical

the

screws securing

the

combustion

front panel and remove panel. Unplug the

supply

leads

for

the

gas control valve from

the control box.

Remove
its

the

support

screw securing

bracket

the

gas

control valve

Disconnect electrode lead from electrode.
Remove

the

gas

two

screws securing

bottom

of

the boiler case and lift

control assembly.

the

burner assembly

out

the

or

burner/

wing

to

to

burner/

13

Supplied By www.heating spares.co Tel. [phone]

LIFTING THE BOILER
Lift the boiler

onto

its mounting

bracket

ADJUSTMENT
SCREWS

FIG.

14

Locate the studs on the air duct flange through the boiler

casing and secure using four wing nuts (accessory pack

F).

0

-LEG

AG.15
Position boiler on

of

wall.

Undo
and discard foot. Vertical alignment with rear
corrected using the adjustment screws at
boiler. See FIGS.

TRANSPORTATION FOOT

its

mounting bracket

the boiler line

the two screws securing

up

with

15 & 16.

the

so

reference lines

the

transportation foot

that

·c·

the

the

sides

on

the

wall can

rear

of

D

rear

be

the

ADJUSTMENT
BASE

PLATE

SECURING SCREW

SCREW

FIG.

If

the

assembly were removed

AG. 16 SECURING BOILER
Rotate the left hand adjustment screw to align one

holes in the base plate with hole 'D' in the
through the hole in the

wall using the screw from accessory pack D.
Make good the wall surface around the flue terminal.
Fit optional terminal

leg, secure the base plate

wall plate

if

required.

wall. Working

of
to

the
the

weight. refit them
of removal. When refitting
assembly ensure that

burner engages correctly into

When refitting the fan/fluehood assembly ensure that
the

retaining

14

17

fan/fluehood assembly

to

the

boiler. Reassembly is

the

rear

of

the fluehood

flange. See

FIG.

or

burner/gas control

to

reduce

the

locating

the

is

correctly located beneath

17.

the

appliance lift

the

reverse

burner/gas control

pin

on

the

rear of

rear support

bracket

the

Supplied By www.heating spares.co Tel. [phone]

ELBOW EXTENSION

SECURING

AG.

18

FLUE

ELBOW

When side fluing, slide the elbow extension onto the
elbow, push on
screw with arrow on

accessory pack
extension and screw
drilling will
the elbow.

When rear
discarded.

fully and align the hole for securing
'C' into the pre-drilled hole

pierce the elbow and secure the extension

fluing, the elbow extension should be

SCREW

EXTENSION

elbow. Engage the screw from

in

elbow

fully home. The screw which is self

to

AG.

19

LOCATION

SENSING

Slide the flue elbow into the flue duct. ensure that the
sealing gasket is in place and the elbow is correctly

located beneath the retaining flange at the rear. See

OF

PRESSURE

TUBES

FIG.

19.

Secure elbow using thumb screw previously removed.
Reconnect flexible tubes to elbow.
ENSURE

The tubes are supplied at

hand flue outlet. When using rear
outlets,
by
point

NOTE

Red
connection on the elbow, each being identified with a
red ring.

THEY

ARE

NOT

KINKED.

the

length required for left

or

right hand flue

to avoid kinking, the tubes should be shortened

150mm. A band around the tube indicates the cutting

tube connects

the

front aluminium tube to

the

lower

FIG.

20

PIPE

CONNEGllONS

Connect system pipework to the boiler, compression
fittings
used it is essential to temporarily remove both of the
thennostat bulbs from the

should be used. lf however capillary fittings are

flow pipe before soldering.

A drain off tap should be
in a low point of the system. Connect the gas supply pipe
to the inlet of the gas cock. Ensure the gas cock is in a

position where it can
controls cover is removed.

15

installed close to the boiler

be

easily operated when the

if

it

is

Supplied By www.heating spares.co Tel. [phone]

ELECTRICAL

The boiler and all external control circuit wiring must

supplied from the same single isolating switch
and

socket

Care must be taken

is kept clear

and should

of

sharp edges and hot surfaces.

be

fused at 3A.

to

ensure that all wiring to the boiler

or

plug

be

EX1'ERNAL
ELECTRiCTJY

SUf>f'LV

EXTlRPiAl 3 Con

~~~~00

FIG.

21

PROGRAMMER

S

to3Cott

CONlAOL
VAlVES

ETC.

PRINCIPLE

JUCTION BOX

OF

WIRING

ROOMANS)/OR

CYllNt>ER

'THERMOSTAT

BOtU:R

SECU::HNG

SCREW

AG. 22 ACCESS

TERMINAL

TO

THE

BLOCK

BOILER

ELECTRICAL

The boiler tenninal

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
this incorporates a junction
shown in AG.

if a Potterton Electronic Programmer is used as

box. The principle of wiring is

21.

Further infonnation on wiring of system controls can be
found in the

Remove control
control

Control System, Pipework and Wiring Guide.

box

securing screw and lower the

box

to gain access to

the

boiler tenninal block.

Remove packaging from rear of the control box.

16

Supplied By www.heating spares.co Tel. [phone]

TEST

SOCKET

GAS CONTROL

VALVE

SUPPL V

LEAD

I I

AG. 23

Following the pump manufacturer's instructions connect
the pump supply wires to
LN
through the plastic bush in the rear of the control box as
illustrated in

Route a four core cable through the plastic bush in the
rear of the
in
follows:­Permanent live to terminal marked MAINS 'L'.
Neutral to terminal marked MAINS 'N'.
Earth to terminal marked'-:!:-' adjacent to cable clamp.

See

Switched live from external controls to terminal marked
MAINS

If there are no external controls fitted connect the

terminal

ROUTING

...L.

on the boiler terminal block. Route the cable

control box and the cable clamp as illustrated

AG.

23 and connect it to the boiler input terminals as

OF

ELECTRICAL

terminals marked

AG.

23 and secure, using the cable clamp.

WIRING

NOTE.

'Swl'.

to

permanent live in the junction box.

PUMP

Swl

FITIING SIDE INFILL PANELS

required, the gap between the casing sides and

If
rear

wall can be closed

off

using the infill panels

supplied.

NOTE:

Ensure that the earth conductor is longer than the
Swl

from the point
carrying conductors become taut before the earth
conductor

When the wiring has been completedt:lose the control

box and replace the securing screw.

if

cable is pulled out of the cable clamp.

of

anchorage, so that the current

L,

N &

Ensure the casing surface is
DRY.

Remove the protective backing paper from the
adhesive strip on the
press into
down the

place, applying FIRM EVEN pressure

FULL LENGTH of contact area between

panel and case.

boiler case

should be warmed prior to application of

infill

If conditions

FULLY CLEAN AND

panel, carefully align and

are

near freezing, the

the infill panel.

FIG. 24

17

Supplied By www.heating spares.co Tel. [phone]

COMMISSIONING

Open

Vented

Remove the pump and flush out the system thoroughly
with

cold

Examine for leaks.

Sealed

NOTE:
The system can

pump
approved
SYSTEM' section Page 8 in these instructions, also
BS

Remove
cold water. Refit the pump.
the pressure gauge registers

Examine for leaks. Raise the pressure until the safety
valve lifts. This should
preset
correct
water gauge to this

All

The whole

should
purged
BS 6891.

Electrical
competent
Wiring Regulations.

Test
Tum boiler thermostat

with a break tank

6798

lift pressure

Systems

pilot unions for gas soundness

Unplug
control box and plug
the boiler thermostat knob, See AG. 23.

on

Tum
Ensure that the time control if fitted is in an

and that the room
fitted are set to high temperatures.

Switch
Gas will

ignition system
Using a leak detection fluid, check pilot unions for

gas soundness.

Tum

off

service cock.

Remove gas control
refit

the

control box. See AG. 23.

Systems

water. Refit the pump. Fill and vent the system.

Systems

be

filled using a sealed system filler

or

by

any other method

by

the

Local Water Authority. Refer

1987.

pump

and flush out the system thoroughly with

RH

and vent the system until

1.5

bar

occur

within ±

of

3 bar. Release water

cold

fill pressure, and set the indicator on the

value.

of

the

gas

installation including the meter

be

inspected and tested for soundness and

in

accordance with the recommendations

testwork

person

the

gas

gas at the gas service cock.

on

the external electricity supply

flow

to

the pilot only.

the external electricity supply and

plug into the socket on the left hand side of

should

in

accordance

to

control valve supply lead from the

it

into the test socket adjacent

and/or

is

de-energised.

valve plug from

be

carried

with

as

the

'O'

position.

cylinder thermostats where

tt

will not

be

th~

test socket and

to

'THE

(21.5 lbf /in2}.

0.3

bar

of

to

attain the

out

by

the

l.E.E.

follows:-

ON

condition,

to

the boiler.

ignited

as

the

to

the

gas

the

of

a

Refit the combustion chamber front panel.

Fit

the

case door into position

hinge brackets and secure it with the lower
screws.

Remove the temporary label
appliance, having ensured compliance
warnings

First

on

the

Ughtlng

label.

by

lifting it onto

from

the

two

front

with

the

top

fixing

of the

the

WARNING: Before lighting the boiler.ensure that the

CASE

DOOR
the sealing strip fitted
seal with the main boiler casing. Before proceeding

light the boiler, check that the external electricity supply
to the

boiler

is

in

the

on

Tum

Ensure that the

are open.

Ensure that the time control, if fitted
and that the room and/or cylinder thermostats, where
fitted are set to high temperatures.

Switch on the external electricity supply

After installation of the appliance, preliminary electrical
system checks must
carried

HAS BEEN CORRECTLY FITTED and that

to

the case

is

switched off and that the boiler thermostat

'O'

position.

the gas service cock.

out

pump

are:-

and radiator isolating valves

be

carried

door

is

forming a tight

is

in an on condition,

to

out

The checks

to

the boiler.

to

be

A Earth Continuity

B.

Short Circuit

C.

Polarity

D.

Resistance

Refer

to

Fault

Tum the boiler thermostat on and
after a period

be

observed through the sight glass in the front cover

the boiler. The time period can vary upwards of

seconds, depending

pipework.

Test for
using leak detection fluid.

Tum
NOTE:
There

switched

gas

the

boiler thermostat

could

on

to

Earth

Finding

of

time the main burner will light, this can

soundness around the boiler components

be

a delay in lighting if

and off and then on again rapidly.

Chart

on

the amount

to

·o·.

FIG.

30

to

a high setting and

of

the

control knob

45

air in the

of

is

SETTING
With the controls cover removed.

Fit a pressure gauge to the pressure test
supply pipe.

Turn
burner
accordance with values stated under TECHNICAL
DATA.

The burner pressure is set to the maximum output at
the factory.

AND

CHECKING

See

FIG.

2.

on the boiler thermostat and ensure that the main

is alight. Check that the burner pressure is

OF

CONTROLS

nipple in burner

in

If

follows, referring

SIT

Remove the plastic
valve
clockwise
decrease the pressure.

HONEYWELL
Turn

increase the pressure

pressure.

18

burner pressure adjustment is necessary

to

AG. 25.

GAS

CONTROL

and

turn the pressure adjustment screw anti­to

increase

the pressure adjustment screw anti-clockwise

VAL

VE

cap

from beneath the gas control

the

pressure

GAS CONTROL

or

clockwise

VALVE

proceed

or

clockwise

to

decrease the

as

to

to

Supplied By www.heating spares.co Tel. [phone]

HONEYWELL

PILOT

SCREW

(For test purpose only)

SPACER

I

SEALS

PRESSURE

FIG.

25

MAIN

BURNER

With the burner set

given

rate
obtained
reading

been
replace the plastic

Shut down the boiler remove the pressure gauge and
refit the screw in the test nipple ensuring that a tight seal
is made.

Remove the self-adhesive arrow from the inspection
ticket tied
Data Plate inside the
appropriate burner setting pressure.

Refit the controls cover.
Relight the boiler

Check for water leaks, turn the
system

Refill the system and
correct
to

the system design pressure.

in

TECHNICAL

and

this

at

least 1 O minutes after the main burner has

lit.

When

whilst hot.

cold

the

to

the burner supply pipe and stick it

fill pressure. Set the pressure gauge pointer

ADJUSTMENT

PRESSURE

to

its correct pressure, the firing

should

pressure

cap

and

on

be

on

the

controls cover

heat the system

sealed systems adjust

SCREW

ADJUSTMENT

DATA

SIT

should

checked

and

rate are

gas

control valve.

to

indicate the

to

boiler off, drain the

also

be

by

meter

correct

to

the

maximum.

to

the

PRESSURE

The thermostat has been calibrated
no

attempt should

the thermostat

main burner shuts down.
Pump

Over-Run

Will keep the
down, as
is

above 80°C.

The thennostat

Overheat

The overheat thermostat is pre-set and no adjustment is

possible.
condition occurs. Access to the reset button is through a
hole in the underside of the controls cover, see

long

Thermostat

It will require manually resetting if an overheat

be

made to re-calibrate it

to

the 'O' ·position and

Thermostat

pump

running after

as

the

water temperature within

is

preset and no adjustment

ADJUSTMENT

by

the makers and

on

check

the

boiler has shut

the

is

SCREW

site. Turn

that the

boiler

possible.

FIG. 2.

Other

All boiler mounted controls are designed
fault should occur they will fail safe.
checking is necessary.

Boiler

Controls

so

No

further setting

that

if

any

or

If a by-pass circuit is fitted the by-pass valve should

adjusted with the boiler operating under minimum load

conditions

boiler

operate under

Pilot

The pilot is pre-set and

pilot flame envelope should cover the electrode tip and

spark earthing strip see

illustrated, remove and clean the pilot as described in

the

Page22.

Boiler

At its minimum and maximum settings, the thermostat
should control the water
mately

to

maintain suff1eient water flow through the

to

ensure that the overheat thermostat does not

normal operating conditions.

Burner

no

adjustment

FIG.

29.

If

Servicing Instructions Section

is

required. The

the pilot flame

4,

PILOT BURNER,

Thermostat

flow temperature at approxi·

55°C-82°C

(130°F-180°F).

is

not as

be

External

Check that any other external control connected in the

system, such as

boiler as required.

User's

A User's Instructions leaflet is provided with this boiler

but the householder must have the operation
boiler
householder must also be advised of the importance
annual servicing and of the precautions necessary
prevent damage to the system and building, in the event
of the system remaining out of commission in frost
conditions.

19

Controls

clocks

Instructions

and

system explained

and thermostats, control the

of

the

by

the Installer. The

of
to

Supplied By www.heating spares.co Tel. [phone]

PERMANENT

LIVE

PUMP

r-----+o+------1

BLACK

l "

B 8

PUMP

.,..___

EJ

SWITCHED

AG.

l!VE

26

FUNCTIONAL

PR

FLOW

OWN

TESl

SOCKET

DIAGRAM

fl

OVERKEAt

THERMOSTAl

BOiLER

THERMOSYAT

WHllE

a-

WHrTE

BLUE

BROWN

EL£C1R0"1JIC

CONlROL

llTlA

1----~----:::..+--:_::

11

12

Sl

S:I

____

13

T•

TS

16

T1

T8

WHITE

BLUE (

1

SLACK

_...

OftANGE IHO•

WP.UTE

9ROWN

____

BLUE

---, y

r

L--(

~~-~-~--I~

iE

GV2

r ---

GVI

'

!NCI

"

~=TROl

VAlVE

AIR

PRESSURE

SWITCH

!Cl

FANN

HONEYWELL

AG.

27

BOILER

WIRING

DIAGRAM.

20

Supplied By www.heating spares.co Tel. [phone]

SERVICING

Regular skilled servicing and cleaning

of

the

appliance

INSTRUCTIONS

is essential to ensure continued safe and efficient opera-

tion. The frequency
particular installation conditions, and the use to which

the

appliance is put, but in general, once per year

should be adequate.
It is the law that all gas appliances are installed and

serviced
(Installation and
For Health and Safety

Electrical installation and servicing should be carried

out

by

competent persons as stated in Gas Safety

by

a competent person

of

cleaning will depend upon

Use) Regulations 1984.

Information see back page.

in

accordance with the

the

l.E.E. Wiring Regulations.

Servicing is best arranged
Potterton Myson Limited and further
from the

The boiler

attached to the inside
CODE NUMBER
ing spares or requesting information
control box.

All parts likely to require servicing are readily accessible.

By

removing the front door from the
components are exposed. Remove the front of the
combustion chamber to gain access to the main and
pilot burner and the ignition electrode.

Removal of the

the flueways in the heat exchanger for cleaning.

The following notes

but it should be remembered that attention must

local Potterton Regional Service Office.

DATA

PLATE

which should be quoted when order-

See

FIG.

removing the cover from the boiler controls and

flue elbow, fan and fluehood will expose

apply to the boiler and its controls

by

a contract placed with

details are available

and WIRING DIAGRAM are

of

the controls cover. The boiler

is on the front

2.

boiler, most

of

the

also oe

paid to the heating circuit itself including radiator valves,

thermostats. the time control and the expansion

teea water system.

immediately after the end
In all cases prior to servicing, light up the boiler and

check that the
flame and that the gas rate and main burner pressure are
correctly set.
servicing

mation given
WARNING

Before
external electricity
plug at the socket
switch.

NOTE: After completing any servicing or replacement
components check for gas soundness and carry
functional checks.

1.

PREPARING THE BOILER FOR SERVICING
See RG.13.

NOTE:

elbow fitted to the fluehood.
The

flued boilers.

A Remove controls cover

B.

If the pilot flame is satisfactory,

of

the pilot burner

the

start of any servicing work, switch off

Tum

off the gas service cock.

Boilers with side or rear flues have a flue

elbow is replaced by an adapter on vertically

covering the securing screw on the underside
the controls cover, see AG.
screw,
to

release it from its four side fixings and pull

forward clear of the thermostat knob.

Remove door
and

lift door off the two upper hinge brackets.

tt

is

advisable to clean the boiler

of

the heating season.

pilot and main burners have a clean, even

is

necessary and the infor-

in

'4. PILOT BURNER' can be ignored.

supply

or

pull controls cover forward 1

by

disconnecting the supply

switching off the external isolating

by

opening the door

13.

Undo securing

Omm,

by

undoing the lower fixing screws

no

<lnd

further

at

the

of

out

lower it

of

GAS
CONTROL

VALVE

PLUG

~-----,

"""'

'

............

,

..

'\

'

...............

,

'\

',

__

'\

'--...

FIG.

28

BURNER AND GAS CONTROL ASSEMBLY

21

·-.,.............__

GAS

CONTROL
VALVE/SUPPORT
BRACKET

SCREW

7BLADESON

30F, 40F,

8BLADESON

80F

BURNER
SECURING
SCREWS

50f

& 100F

& 60F

Supplied By www.heating spares.co Tel. [phone]

C.

Remove screws securing
front panel and remove panel.

D.

Disconnect

E. Remove

withdraw

On

vertically flued boilers remove

and

slide the vertical flue adapter

duct.

F.

Disconnect
connector adjacent
nuts

out

Lift
Lower and

G.

Undo the union on

H.

Unplug
valve from control box. See

I.

Remove
its support

J.

Disconned

K Remove

the

bottom

and gas control assembly.

the

two flexible

thumb

securing the flue

fan/flue

the

the

two

screw securing

elbow. Take care

the

fan

supply

to

hood

lift

out vertical adapter.

the

electrical supply leads

screw securing

bracket

the

screws securing

of

See

electrode lead from electrode.

the boiler case

the

combustion

tubes

from
the

notto

damage

two

up

and earth leads from

the

fan. Remove

hood

to

the

heat exchanger.

assembly.

gas

service

FIG.

FIG.

cock

for

28.

the

gas control valve

28.

the

burner assembly

and

lift out

chamber

the

flue elbow.

flue elbow and

the

gasket.

thumb

the

screws

into

the

the

two

outlet.

gas control

the

burner

flue

the

wing

to

to

B. Unscrew

the
assembly
the

operation.

C.

Lightly brush
Remove
replace.

pilot
pilot

the

to

and

injector

the

NOTE

Do

not

use a wire brush

D.

Gently clean

E.

Refit

the

assemble

F.

Secure
two

the

hexagonal screws.

G. Fully tighten

to

the

pilot.
following
commissioning

18.

H.

Ensure that

two

the

pilot

any

pilot

the

pilot

the

Check

the

the

hexagonal

main

shield

does

the

pilot

injector

deposits from

injector

pilot

to

assembly

union

for

procedure described

sedion

spark gap

head

burner

where

and

fitted,

not fall out during

to remove

and

clean its orifice

or

pin

to

the

to

the

the

pilot

tube.

to

the

nut

connecting

gas soundness

of

these

is

as illustrated in

screws securing

remove pilot

be

careful

any

clean injector.

electrode.

pilot burner

main burner using

the

at

instrudions.

that
this

deposits.

pilot

this

joint

in

FIG.

or

and

tube

by

the

Page

29.

2.

HEAT EXCHANGER

A

Working from above and below

use

a suitable tool and remove all deposits from

between the fins.
Slide vertical flue adapter into flue duct.

3.

FAN

A Separate fan from fluehood

securing screws.
carefully clean any deposits from around the fan

motor and its supports. Examine the fan
clean if necessary using a soft brush.

Re-assemble fan to fluehood ensuring that
sealing gasket is in place and in good condition.
Ensure also that the fan

retaining
Secure with

B.

Refit
rope seal
correctly located beneath
FIG.

C.

Slide flue elbow into

adapter and secure with

the

undamaged and in place.

D.

Reconnect the

ENSURE

bracket

two

the

fan/fluehood assembly. Ensure that
is

in

place and

17. Secure with

gasket between fan outlet and elbow

THEY

ARE

NOTE

Red tube
connection on elbow

identified with a red ring.

E.

Reconnect the fan supply and earth leads.

conneds

is

screws.

two

the

fl~xible

tul:>es

NOT

front aluminium tube

the

heat exchanger

by

removing

wheel and

located

the

wing nuts.

thumb

corredly

rear

of

the

fluehood

the

retaining flange. See

flue

dud

or

screws. Ensure

or

to

elbow

or

KINKED.

to

or

adapter each being

the

two

the

in

the

rear

the

is

lower flue

that

adapter

the lower

is

adapter.

RG.

PILOT FILTER

5. COMBUSTION CHAMBER INSULATION

A

6. MAIN BURNER

A.

4. PILOT BURNER

The following operations are only necessary if the pilot

is

flame

distorted

A Unscrew the pilot tube from

care not

or

the wrong size, ie

the

to

damage the electrode.

too

small.

pilot assembly. Take

22

29

PILOT

The

pilot

filter

situated
large
valve
therefore unlikely

event of pilot filter blockage
complete control valve should

Check
damage. If damaged replace as described

replacement.

Lightly brush any deposits from
and ensure there

venturi.

incorrect
cannot
control assembly
Clean
procedures not
disconnect
the

flanged connection and replace

injector.

BURNER

burner

within

and

designed

under

or

normal operating conditions,

the

combustion

If

on re-assembly
or

the

be

obtained, remove

replace

the

SPARK GAP TOLERANCES

is

proteded

the

to

to

need

is

no

correct gas rate

and

the

injector. In

rectifying

burner from

from blockage

gas

control valve. The filter

last

the

life of

the

replacing. However in

being

suspected

be

replaced.

chamber

fluff

in

the

the

bumerflame

thoroughly

the

the

the

insulation

the top

entry

or

burner

the

burner

clean

event

flame appearance,

gas

control valve at

the

by

gas control

of

each blade

of

the burner

picture

pressure

and

the

of

the

burner and

a pilot

is

it

is
the
the

for

under

is

gas

burner.

above

Supplied By www.heating spares.co Tel. [phone]

B.

Refit

the

burner and gas control valve assembly into

the

boiler, ensuring

burner engages correctly into

bracket
and undamaged between
case. Secure

C.

Refit

support

D.

Reconnect electrode lead

E.

Plug gas control valve

F.

Reconnect gas
on gas.

G.

Refit
CASESEAL

7.
Check

seal is
door.

RECOMMISSION

8.
Follow

in the COMMISSIONING section
instructions page

9.

OTHER BOILER MOUNTED UNITS

No further servicing
mounted units. Repair

10.

FAULT FINDING

Refer
Diagram

REMOVAUREPLACEMENT OF BOILER
MOUNTED UNITS

Make sure

the

screw securing

bracket

the

combustion

the

case

simply pressed into

the

full commissioning procedure as detailed

to

Fault Finding Chart AG.

RGS. 26, 27.

that
that

the

assembly with

supply

supply

chamber

door

seal. Replace

18.

is

the

locating

the

the

sealing gasket

the

burner flange

two

the

gas control valve

to

electrode.

leads into control box.

at gas service

front panel.

the

channel around

required on any

is

by

replacement

pin

on

the

rear

rear support

is

in

place

and

screws.

to

cock

and turn

if

damaged. The

of

other

30

and Wiring

of

the

the

the

these

boiler

MAIN BURNER

1. Switch off

disconnecting
the

external isolating switch.

the

external electricity

the

plug

at

2. Remove controls cover, case

chamber front
the

Boiler

3. Remove

described in
operations

4. Unscrew

pipe

to

the

to

damage

injector does

Remove
tube through the hole

5. Separate

flanged connection

screws.

NOTE: With

is

used

between

flange, requiring

See

FIG. 25.

6.

Unscrew

pressure test

panel as described

for

Servicing', operations

the

burner and

1.

'Preparing

G,

H,

I,

J & K

the

union nuts connecting

pilot and gas control valve. Take care not

the

electrode and

not

fall out during

sealing grommet and withdraw

in

the

the

burner from

by

removing

the

Honeywell

the

the

the

pilot, main burner injector and

nipple from

valve

use

gas

of

7. Use new sealing gaskets

8. Replacement

9. Follow

the

in

the

instructions. Page

is

the

reverse

full commissioning procedure as detailed

COMMISSIONING section

18.

supply

the

socket

gas

the

be

burner mounting flange.

the

gas control valve

control valve a spacer

outlet

two

the
on

of

or

switching off

door

and combustion

in

1.

'Preparing

A,

B and

control assembly as

Boiler

for

Servicing',

the

pilot supply

careful that the pilot

this

operation.

the

the

four

securing

and

the

burner

seals

at

this

burner.

reassembly.

removal.

of

by

C.

pilot

atthe

point.

these

GAS CONTROL
This operation

the burner and gas control valve

1.

Switch off the external electricity
necting
external isolating switch.

2. Remove controls cover, case

chamber front
the

Boiler for Servicing', operations A, B and

3.

Remove
described in

operations

4. Disconnect the electrical supply from the

Honeywell, note the individual wire positions.

With

Refer to

5. Unscrew the union connecting

to

the

6. Separate the gas control valve from

the

inlet and outlet ports

screws.

NOTE: With the Honeywell gas control valve a spacer

is

used

between

flange, requiring

See FIG. 25.

7.

Use new seals on reassembly.

8. Replacement

9.

Follow

the

in
instructions. Page

VALVE

is

most easily carried out

the

plug at

the

G,

FIGS.

gas control valve.

the

full commissioning procedure as detailed
COMMISSIONING section of these

the

socket

panel as described

burner and gas control assembly

1.

'Preparing

H,

I,

J & K

26

and 27.

the

valve

the

use

is

the reverse

18.

of

the

by

outlet

two

by

first removing

assembly as follows:-

supply

or

door

Boiler

the

removing

seals

of

removal.

by

switching off

and combustion

in

1.

'Preparing

for

Servicing',

gas

pilot

supply

the

flanges at

the

and

the

at

this

discon-

the

C.

as

valve.

pipe

securing

burner

point.

PILOT

1. Switch off

2. Remove controls cover, case

3. Disconnect

4. Unscrew

5.

6. Replacement

7. Follow

COMBUSTION CHAMBER INSULATION

1. Switch off

2. Remove controls cover, case

23

/IGNmON

necting the
external isolating switch.

chamber
the

Boiler for Senricing', operations

assembly. Take care
Unscrew

the

pilot

assembly and shield where fitted,

pilot injector
Unscrew electrode retaining

electrode.

assembly ensure that
in

AG. 29.

in

the

instructions. Page

necting
external isolating switch.

chamber front

ELECTRODE

the

external electricity supply

plug at

front panel

the

the

the
to

the

the

full commissioning procedure as detailed

COMMISSIONING section

the

the

plug

the

socket

as

electrode lead from electrode.

aluminium pilot

not

two

hexagonal head screws securing

main

burner

does

not

fall

is

the reverse of removal.

the

18.

external electricity supply

at

the

panel as described in

or

door

described

tube

to

damage

and remove

out

during

nut

spark gap

socket

door

by

discon-

switching off

and combustion

in

1.

'Preparing

A,

B

and

from

the

the

electrode.

the

be

careful that

this

operation.

and withdraw

On

is

as illustrated

of

by

discon-

or

switching off

and combustion

1.

'Preparing

the

C.

pilot

pilot

the

the

re-

these

the

Supplied By www.heating spares.co Tel. [phone]

the Boiler for Servicing', operations A, B and C.

3. Remove main burner as described

Boiler for Servicing•, operations G,

4. Bend

5. Replacement

back

retaining tabs and replace insulation. It
necessary
replacing the rear.

to

first remove

is

the reverse of removal.

the

in

'Preparing

H,

I,

J & K

side insulation

the

is

when

6. Follow the full commissioning procedure as detailed

in the COMMISSIONING section of these

Page

instructions.

FUSE,

ELECTRONIC
BOILER
PUMP

The following initial operations 1-3 are necessary to

remove and replace any

1.

2.

THERMOSTAT,

OVERRUN

SWitch off the external electricity
disconnecting the plug at the socket
the external isolating switch.

Remove controls cover
covering the securing screw
controls cover see AG.
pull controls cover forward 10mm, lower

it from its four side fixings and pull forward clear

the thermostat knob.

3.

Remove control box securing screw and lower
control box.

FUSE1

4. The fuse

amp

is

be replaced

located on the electronic control and can

5. Replacement

FIGS.

26 & 27.

ELECTRONIC

CONTROL

4. Disconnect

electrode lead from the electronic control. Refer
FIGS.

26 & 27.

Disconnect the flying
as follows:-

white wire from terminal C(3)
thermostat

white wire from terminal NC
thermostat

brown wire from overheat thermostat
blue wire from boiler terminal
green/yellow wire from earth

5. Release the control

lugs.

6. Remove electronic control.

7. Replacement

8. Follow the full commissioning procedure as detailed
in the

COMMISSIONING section of these instruc-

tions. Page

PRESSURE

4.

Remove the screw securing the pressure switch
the bracket in
from bracket.

5.

Disconnect the
tube is connected to

SWITCH

18.

CONTROL.

OVERHEAT

THERMOSTAT

of

PRESSURE

the

above items.

by

on

THERMOSTAT,

or

opening

the underside

13. Undo securing screw,

by

lifting it from its holder.

is

the reverse of removal. Refer

six

way plug,

leads of the electronic control

by

lifting it from

is

the

reverse of removal.

18.

the

control box. Lift pressure switch

two

plastic tubes. NOTE: the red

the

two

way plug and

of

(2)

of

block

connector N

post

the

pressure switch connec-

SWITCH,

supply

switching off

the

it

to

the

the control

four

by

door

of

the

release

of

to

to

control

retaining

to

lion

identified with a red ring,

6.

Disconnect the three electrical leads, white wire
from terminal No. 1

or

NO and brown from terminal No. 3

AGS26

& 27.

7. Replacement

the

plastic tubes have

positioned

8. Follow

detailed
instructions. Page

OVERHEAT

4. Remove

screws and lifting

brackets.

the

in

THERMOSTAT

door

5. Disconnect

the

from

overheat thermostat terminals.

6. Remove the

to

its mounting bracket.

or

NC, orange from terminal No. 2

is

the

reverse

to

prevent

full commissioning procedure as

the

COMMISSIONING section

the

18.

by

undoing the

door

the

two

push

nut

securing the overheat thermostat

7. Noting the route taken

pin

retaining

from its pocket. Remove the split grommet

base of the boiler, feed the thermostat capillary and
bulb

through the hole.

8. Replacement

rubber grommet
good

capillary
AG. 2. The
coated with heat conducting paste.

9. Follow

detailed
instructions. Page

BOILER

THERMOSTAT

4. Remove

screws and
brackets.

5. Disconnect

White from tenninal C(3). White from NC(2)
Refer

6.

Pull off

7. Remove inner thermostat post

securing screws.

8. Remove the
control box.

9. Remove the

flow pipe.

10. Remove the
Feed

Replacement

the new thermostat should

conducting paste. Ensure the
the base of
capillary.

Ensure that
provided.

Follow the full commissioning procedure as
detailed

instructions. Page

the

thermostat

is

the

reverse

in

the base of

seal around

is

secure
bulb

the

in

the COMMISSIONING section

door

the

to

RGS.

the

outer thennostat knob.

clip

the

capillary and

the

in

the COMMISSIONING section

the

in

of

the

full commissioning procedure as

18.

by

undoing the

lifting

door

electrical connections as follows:-

26

& 27.

nut

securing the thermostat to

securing the thermostat

split

grommet

is

the

reverse of removal. The

boiler make a

the

capillary

18.

or

adjacent red

or

C. Refer

of

removal. Ensure that

the

coiled springs

tubes from kinking.

two

lower

off

the

two

upper

on electrical connections

by

the capillary, remove split

bulb

and

withdraw

of

removal. Ensure the

the

boiler makes a

capillary. Ensure that

the

clips provided. Refer

new thermostat should

two

lower fixing

off

the

two

upper

by

undoing the

in

the base

bulb

through the holes.

be

rubber

good

is

secure

of

coated with heat

grommets

seal around

in

of

of

bulb

the

the

of

spot

to

these

fixing

hinge

bulb

in

the

the

to

be

these

hinge

two

the

to

the

boiler.

bulb

the

clips

these

of
in

24

Supplied By www.heating spares.co Tel. [phone]

PUMP

OVER-RUN

4. Remove
and lifting

door

5. Disconnect

THERMOSTAT

by

undoing

door

off

the

two

the

electrical connections

1 red wire from terminal N0(4)

2 brown wires from terminal NC(2)

1

black

wire from terminal C{3)

6. Remove

control box.

7. Remove the

flow pipe.

8. Remove

Feed the capillary and

9. Replacement is

the

conducting paste. Ensure
makes a good seal around

10. Ensure that

provided. Follow

as detailed
these instructions. Page

SIGHT
WARNING:

HANDLING
GLASS.

3. Remove
and

4. Remove three

the

screw securing

clip

securing

the

split

grommet

bulb

the

reverse

new thermostat should

the

capillary

the

full commissioning

!n

the

COMMISSIONING section

GLASS

GREAT CARE SHOULD BE TAKEN WHEN

AND

DISPOSING OF A BROKEN SIGHT

door

by

undoing

lift

door

off

the

two

M4

nuts from

the

lower fixing

upper

hinge brackets.

the

thermostat

the

thermostat

in

the

base

through the hole.

of

removal. The

be

coated

the

rubber

the

capillary.

is

secure in

18.

the

lower fixing screws

upper

hinge brackets.

sight

glass retainer and

screws

as

follows:-

to

bulb

to

of

the

boiler.

bulb

with

grommet

the

procedure

the

the

of

heat

clips

of

remove

5.

Replacement
that
viewing
new
fitted.

sight

the

clear circle

hole

gaskets

glass assembly.
is

the

reverse

in

combustion

must

be

in

used

of

the

See

above.

removal. Taking care

sight

glass lines

chamber

when

FAN

1.

Switch
disconnecting
off

2.

Remove
in

A and

3.

Djsconnect
elbow.

4. Remove

withdraw
gasket.
thumb
into

5.

Disconnect
connector adjacent

6. Separate fan from

securing screws.

7.

Replacement
reassembly
rear retaining bracket.

Follow the full commissioning procedure

8.
detailed
instructions. Page

off

the

external electricity

the

plug

the

external isolating switch.

controls

t 'Preparing

cover

the

Boiler

B.

the

two

thumb
On

screws and slide

the

flue duct.

screw securing

elbow. Take care

vertically flued

the

fan

supply

to

fluehood

is

the

reverse of removal. Ensure

that

the

fan

in

the

COMMISSIONING section of these

18.

at

the

socket

and case

for

flexible

the

the

is

door

Servicing', operations

tubes

the

not

boilers

vertical flue adapter

and

earth leads from

fan.

by

removing

correctly located

to

door. NOTE

sight

glass

supply

or

switching

as

described

from

the

flue

elbow

damage

remove

the

in

up

is

by

flue

and

the

two

up

the

two

on

the

as

25

Supplied By www.heating spares.co Tel. [phone]

~

Cheek

lull operational

;eqwnct1

to

!ht

Qvtrrvn thermo,1at are

OP•ratrng eorrtc11v

tntun

boifer

31'\dpump

Chtck

pump

ootrating

.find

w•tet

''

c~rculifing

correctly.

Prest

ovtrheat

r•HT

buHon.

is

'hal

Call for heat

En1ure

thut

24Q.!IO%

L & N ond

10%

bttmten

and N.

''

botw"n

240v

SwL.

t

TEST

PROCEDURE

CURRENT
Honeywell
Disconnect

valve

and

as

shown.
ammeter
Tum

ON

NOTE:

GV2

is

disconnected.

When

the

This

will

to

be

measured.

Ooes

ftn

run

withou•

c:vc.ling

on/off

NO

Valve

the

white

connect

in
the

The

pilot

stop

it

Set

test

series

with

electricity

pilot

will

Is

established

the

spark

WHITEWIFIE
01$CONNECTEO

PROMGV2

helec:tr~

soarking 1

---.---

NO

NO

0

1t

there 240v

•l-10%

b<rtwtonT2

ondT4

on •IKttonic

control

0

Enwft

•ir

i:>reuure

tubes

tre

not

kinktd

or

blocked

ar•

correctly

fit

ltd

FOR

MEASURING

wire

from

via a suitable

switch

to

OFF.

the

spark

supply

and

light

but

set

and

allow a steady

f

tnd

GV2

test

Insert

electrode.

restart

not

the

the

test

~

Yi:

FLAME

on

gas

switch

an

the

main

switch

flame

TEST

SWITCH

_...;

~twnn

T2&T3on

electronn;

control1

control

to

neutral

approved

boiler.

burner

to

ON.

current

{ Ooe1Pl101

ught

?

0

It

there 240v

t 1()%

NO

Replacv

el4c:tronie

control

as

N

TEST
CURRENT

S.l.T.Valve
Switch

boiler

control

Insert
electrode.
external
which
current

YES

ltg~isno1

Howm9out
of

i1

PROCEDURE

off

external

door.

Unplug

box

and

an

approved

Turn

electricity

can

now

to

be

measured.

Ooespitot I Y..fS
ntrnain lit?

~burner

NO

pilot

cheek jet

not

biocked

FOR

MEASURING

plug

electricity
the

it

gas

into

control

the

supply

test

ammeter

boiler

thermostat

supply.

lit

manually,

/ooesmam

off

mort

rteordtd?

Gas

I

H!Jht

7 I

NO

NO

txtern•i

supply

the t Ht

It

th•n

be

Switch

tl~tridty

~'::c':d~

Uescribedabove.

there

1.5).IA

FLAME

to

boiler.

supply

lead

socket.

(See

in

series

with

to

OFF.

Re-instate

will

flow

to

the

enabling a steady

Y~

YES

Choe~

GV2.rll>feco

neceuaty

l.!!!___

Remove
from

FIG.

23).

the

spark

pilot

only,

flame

!Ooe5boi!ercycle

off

control

lhtrmouat

SYl19M

ttmptraturt,

nett

solenoid

If

FLAME
With

the

SUPERVISION

boiler

running,

TESTING

turn

off
Temporarily restrict the pilot gas supply
screwing

the

at the boiler thermostat; a spark will
indicating

boiler
complete

the

light

•nd

on

under

of

1h'e

when

is

VP

to

S.•

NO

bo•!•t

in

the

GV2

will

not
anti-clockwise

in

the

normal

Followifig a run

period

temPtr•ture,doH

pump

cperatt

thermoslll

QPertt•t?

gas

valve

pilot

screw

is

electrically disconnected,

light.

Now

re-instate

turns);

manner.

SI

Boilero1mottt/

1t

maximum

eori1inu•

the!'

NO

boiler

without

trippiog

ovwrhHt

to

>thenrQUltl

-......-

Are
o_pen

cm;ulatil'9

i;orreetly

at

pilot

au

~ct

the

the

NO

lr'tlve•

boiler

clockwise.

pilot

and

main

v..i;;s

lh•

Wilter/

thermostat.

by

Tum

be

present,

and

supply

(three

boiler

&oiler

operating
wtltfactorv

YES

1

fully

on
the
will

Ch

..

k

•lee

Is

thtrt

240v

l0%between

T6&T2on

ele<:tror11c

t

YES

control~

NO

nod•

l•edand

replace

n.cen1ry

if

Chect<

sol•no1d

GV1

replace

if

ntcentry

FIG.

30

FAULT

FINDING

Cheek

pilot

it

partially

CHART

NO

that

not

b!o<:ked,

Replace

electronic
conti'ol

RIPltK:'.•

boiltr

thermoJt.,'

Sn

rlaleo

note

Repla"

pump

OVtM'\fn

thermostat

---.----

Reolace

thermontt

owrneat

Supplied By www.heating spares.co Tel. [phone]

SHORT

KEY No. P.l.L

PARTS

LIST

Part No.

G.C.

Part

No.

1
2

3

4

5

6
7

8
9

10
11

12
13 Electronic Control 407677
14 Fuse
15
16 Pressure Switch - Honeywell C6065A 1192

17

18 Overheat Thermostat LM7 P8503

19 Main Burner Gasket

20

21

Pilot and Electrode Assembly including items 2-4
Pilot Injector
Shear Off Union 30F-80F Boiler
Olive

Nut
Electrode
Electrode Lead
Control Thermostat K36 L 1
Gas Control Valve Kit

Gas Control Valve
Gas Manifold Gasket 212105 337 480
Gas Manifold

Pump Over-Run Thermostat K36 P2302
Flue Elbow

Thermostat Knob

Fan Assembly - SEL (c.w. Gasket) 30F-60F Boiler

Fan Assembly -

2.9mm Injector - Main Burner 30F Boiler

3.1

mm Injector - Main Burner 40F Boiler

3.Smm Injector - Main Burner 50F Boiler

3.6mm

4.4mm Injector - Main Burner 80F Boiler

4.7mm Injector - Main Burner100F Boiler
Flue Scraper

Sealing Gasket

(1

amp) T1A

Injector - Main Burner 60F Boiler

100F Boiler
100F Boiler

014

Honeywell

Kit-

SIT Tandem 0830010

·o·

Ring 401637

SEL (c.w. Gasket) 80F & 100F Boiler

VR4700E1034

907739 337 969
402915
402350
402944

402955
402925
407698 337 863
404504
907704
909029

404507
225091

907604

225251

642220
909000
909001
404495

212085 337
410965 337 374
410966 337 375
410967
410984
410969

410985

907736

381

656
357 714
337 859
337 858
382 448

358853

395

796

289

396

337 467
378024
338 316

382 462
337 338

338

445

378036

338 318
338319
382 455

371

337 376
338343
338378
388344
337 862

1

4

15

({)

7

~'

.

·: . ";_!

~µ

"·

.

·, )

..,

..

..,

0

~A"'

~9

0

10

8

cJ.

11

12

"'

~4

20

~

6

i

!)

"''

~

t8j"

•

27

Supplied By www.heating spares.co Tel. [phone]

HEALTH

AND

SAFETY INFORMATION FOR

THE

INSTALLER

the Consumer Protection

Under
197

4.

we are required

Small

quantities of adhesives and sealants used in the product are cured and present no

to

provide information

Act

AND

1987

and section 6

SERVICE ENGINEER

of

the Health and Safety at Work Act

on

substances hazardous

to

health.

known hazards.
The following substances are

also present.

Insulation & Seals

Material

Description

Known Hazards

Ceramic Fibre;
Alumino

- Silicone Fibre
Boards, Ropes, Gaskets
Some people can suffer reddening and itching

the skin. Fibre entry into the eye will cause

Precautions

foreign

Irritation to respiratory
People with a history

particularly
High dust

harsh

body

irritation.

tract

of

susceptible to irritation.

levels are only likely

abrasion.

skin complaints may be

to

arise following

In general, normal handling and use will not

present discomfort. follow

good hygiene

practices, wash hands before consuming food,

First Aid

drinking or using the

Medical attention· must be sought following eye
contact

or

prolonged reddening of the skin.

to!let.

of

Thermostat

Material

Description
Known Hazards

Precautions

First Aid

Sales Enquiries:

Sales Department

Eastem

Avenue

Team Valley Trading Estate
Gateshead

Tyne&

Wear

NE11

OPG

Tel:[phone]

Fax:

0191

491

4466

7568

Warwick Operations, Portobello Works. Emscote Road, Warwick

Service Enquiries:

SeMce Department

House

Brooks

01926

01926

Road

496896

410006

Coveoll'y
Warwick

CV344ll

Tel:

Fax:

Made in England

Contains very

small quantity

of

xylene.
Sealed phial and capillary containing liquid.
Irritating

to

skin, eyes and

throat

Vapour is harmful.

Inflammable
Do

not incinerate.

do

not extinguish with water.

Avoid contact with broken/leaking phials.

Do not purposely puncture.

Eye/skin

contact. wash with clean water, seek

medical attention.

Spares

Enquiries:

Parts

Division
Oueeosway
Leamington Spa
Warwickshire
CV313RG

Tel:

01926 880600

Fax:

01926

880680

By:

Potterton

Technical Helpline:

Technical Department

Brooks House
Coveoll'y
Warwick

CV34

Tel: [phone]
Fax:

Myson

Road

4ll

01926

Limited

410006

CV34

Training Administration:

Unit 5, Titan Business Centre

Spartan Close

Tachbrook Park

Leamington Spa
Warwickshire CV34 6RS

Tel:

01926

Fax: [phone]

430481

50U

All descriptions

POTTERTON

and

illustrations provided in this leaflet have been carefully prepared but

and improvements in

~

Registered Office: Myson

our

products which

MYSON

~.Railway

may

affect

the

accuracy of

All

goods

are sold subject to

on

available

Terrace, Rugby. Warwickshire CV21 3JH. Registered No. 412935

request.

we

reserve

the

information contained in this leaflet.

our

standard conditions

the

right to make changes

of

Publication No. 559573/0195

sale which are