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.
ACCESSORIES - Page 3 The following Potterton Myson controls are recommended for use with your boiler:Electronic Programmer EP2001, EP3001, or EP6000 Cylinder Thermostat PTT2 or PTT1 00 Room Thermostat PRT2 or PRT1 00 Frost Thermostat PRT1 00 FR Motorised Zone Valve M5V222 or M5V228 Motorised Diverter Valve M5V322 Thermostatic Radiator Valve Data sheets describing these products are available on request.
SITE REQUIREMENTS - Page 4 FIG.
SITE REQUIREMENTS - Page 5 Where the installation of the boiler will be in an unusual location, special procedures may be necessary and BS 6798 gives detailed guidance on this aspect. 50mm (2 in) at the top (measured from the top of the boiler case), except where the optional extra pump cover is to be fitted, when 178mm (7 in) should be allowed. Ensure that the gas supply pipe and meter are large enough for this appliance and any others that may be run off the same meter.
SITE REQUIREMENTS - Page 6 ALL MODELS REAR OR SIDE FLUEING MAXIMUM LENGTH ‘X’ STANDARD FLUE SYSTEM 510mm (20in) 1 METRE FLUE SYSTEM 955mm (37in) FIG. 4 FLUE LENGTHS ELECTRICITY SUPPLY A 240 volts -~ 50Hz, single phase electricity supply fused to 3 amperes, must be provided in accordance with the latest edition of the I.E.E. Wiring Regulations and any other local regulations that may apply.
SITE REQUIREMENTS - Page 7 BOILER SIZE Min INJECTOR SIZE GAS RATE m3/h (ft3/h) INPUT kW(Btu/h) OUTPUT kW(Btu/h) BURNER PRESSURE mbar in wg 2.9mm 0.73(25.8) 0.9(31.95) 1.05(36.92) 7.83(26702) 9.69(33068) 11.20(38217) 5.86(20000) 7.33(25000) 8.79(30000) 5.9 7.8 10.4 2.4 3.1 4.2 3.1mm 1.09(38.34) 1.24(43.8) 1.39(49.23) 11.63(39682) 13.29(45336) 14.93(50955) 8.79(30000) 10.26(35000) 11.72(40000) 8.4 10.8 13.4 3.4 4.3 5.4 3.5mm 1.39(50.23) 1.58(55.74) 1.75(61.84) 15.24(52000) 16.90(57692) 18.
SITE REQUIREMENTS - Page 8 The System The boiler must be used on INDIRECT hot water systems only. It is suitable for use on open vented gravity domestic hot water/pumped central heating systems or, fully pumped systems which may be sealed or open vented. necessary. The total length of the by-pass circuit taken from the boiler connections should be greater than 4 metres of 22 mm pipe. It should be fitted with a lockshield valve and be adjusted to maintain a minimum flow through the boiler of 4.
SITE REQUIREMENTS - Page 9 Vessel Charge Pressure(bar) 0.5 1.0 Method of Make-Up Provision shall be made for replacing water loss from the system either:— i) from a make-up vessel or tank mounted in a position higher than the top point of the system, and connected through a non-return valve to the system on the return side of hot water cylinder or the return side of all heat emitters.
SITE REQUIREMENTS - Page 10 FIG 7. FULLY PUMPED SEALED SYSTEM FIG 8.
INSTALLATION INSTRUCTIONS - Page 11 It is the law that all gas appliances are installed and serviced by competent persons as stated in Gas Safety (Installation and Use) Regulations 1994. For Health and Safety information see back page. Electrical installation and servicing should be carried out by a competent person in accordance with the I.E.E. Wiring Regulations. The boiler and its associated equipment will arrive on site in two cardboard cartons. The contents of each carton is as follows.
INSTALLATION INSTRUCTIONS - Page 12 CUTTING AIR/FLUE DUCTS FIG. 11b REAR FLUE FIG. 11a SIDE FLUE 1. 2. Measure from outside face of wall to the side of boiler casing reference line (dimension ‘x’). Take air/flue duct assembly and measuring from the flanged end, mark and cut the outer duct and inner flue duct to dimension ‘x’ plus 20mm. Ensure that both ducts are cut squarely. 1. 2. Measure wall thickness (dimension ‘Y’).
INSTALLATION INSTRUCTIONS - Page 13 FIG. 13 SECTIONAL VIEW OF AIR/FLUE DUCT ASSY THROUGH WALL 5. 4. Protect duct where it is likely to come into contact with mortar by using adhesive tape provided (accessory pack E). Insert the assembly into the wall sliding the rope sealing ring along the air duct into the flue sealing collar. Bend the six tabs on flue sealing collar inwards to retain the rope sealing ring. Ensure air duct flange studs do not obstruct lifting of boiler onto mounting bracket. FIG.
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 casing and secure using four wing nuts (accessory pack F). Position boiler on its mounting bracket so that the sides of the boiler line up with the reference lines ‘C’ on the rear wall. Undo the two screws securing the transportation foot and discard foot.
INSTALLATION INSTRUCTIONS - Page 15 FIG 20. PIPE CONNECTIONS FIG. 19 LOCATION OF PRESSURE SENSING TUBES Slide the flue elbow into the flue duct and locate the flange over the studs on the fluehood ensuring that the sealing gasket is in place. Secure the elbow to fluehood using the four brass securing nuts. Reconnect flexible tubes to elbow. ENSURE THEY ARE NOT KINKED. NOTE: Red tube connects the front aluminium tube in upper chamber to the lower connection on elbow, each being identified with a red ring.
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.
INSTALLATION INSTRUCTIONS - Page 17 FIG. 24 ROUTING OF ELECTRICAL WIRING Following the pump manufacturer’s instructions connect the pump supply wires to terminals marked PUMP L,N, ‘ ’-on the boiler terminal block. Route the cable through the plastic bush in the rear of the control box as illustrated in FIG. 24 and secure, using the cable clamp. Route a four core cable through the plastic bush in the rear of the control box and the cable clamp as illustrated in FIG.
COMMISSIONING - Page 18 Open Vented Systems Remove the pump and flush out the system thoroughly with cold water. Refit the pump. Fill and vent the system. Examine for leaks. Refit the combustion chamber front panel. Sealed Systems NOTE: The system can be filled using a sealed system filler pump with a break tank or by any other method approved by the Local Water Authority. Refer to ‘THE SYSTEM’ section Page 8 in these instructions, also BS 6798 1987.
COMMISSIONING - Page 19 FIG. 26 MAIN BURNER PRESSURE ADJUSTMENT With the burner set to its correct pressure, the firing rate given in TECHNICAL DATA should also be obtained and this should be checked by meter reading at least 10 minutes after the main burner has been lit. When the pressure and rate are correct replace the brass cover screw on WHITE RODGERS gas control valve. Shut down the boiler remove the pressure gauge and refit the screw in the test nipple ensuring that a tight seal is made.
COMMISSIONING - Page 20 FIG. 27 FUNCTIONAL FLOW DIAGRAM FIG.
SERVICING INSTRUCTIONS - Page 21 Regular skilled servicing and cleaning of the appliance is essential to ensure continued safe and efficient operation. The frequency of cleaning will depend upon the 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 by competent persons as stated in Gas Safety (Installation and Use) Regulations 1994.
SERVICING INSTRUCTIONS - Page 22 C. Remove screws securing the combustion chamber front panel and remove panel. D. Disconnect the fan supply leads from the connector adjacent to the fan. Remove the pilot injector and clean its orifice or replace. NOTE: Do not use a wire brush or pin to clean injector. E. F. G. H. Remove the screws securing the fan mounting plate leaving in place the three screws identified with a red circle or adjacent ‘F’ mark in fan plate. Remove mounting plate complete with fan.
SERVICING INSTRUCTIONS - Page 23 C. Refit the screw securing the gas control valve to the support bracket. D. Reconnect electrode lead to electrode. E. Plug gas control valve supply leads into control box. F. Reconnect gas supply at gas service cock and turn on gas. G. 6. C. D. 7. 8. 9. 7. Use new seals on reassembly. 8. Replacement is the reverse of removal. 9. Follow the full commissioning procedure as detailed in the COMMISSIONING section of these instructions. Page 18.
SERVICING INSTRUCTIONS - Page 24 chamber front panel as described in 1 .‘Preparing the Boiler for Servicing’, operations A, B and C. white wire from terminal C (3) of the control thermostat white wire from terminal NC (2) of the control thermostat 3. Disconnect the electrode lead from electrode. 4. Unscrew the aluminium pilot tube from the pilot assembly. Take care not to damage the electrode. brown wire from overheat thermostat 5.
SERVICING INSTRUCTIONS - Page 25 7. plate, leaving in place the three screws circled red, and remove the plate complete with fan. GRAVITY HOT WATER/PUMP OVER-RUN THERMOSTAT. Refer to FIG. 2. Disconnect the electrical connections as follows:— 4. Remove door by undoing the lower fixing screws and lifting door off the two upper hinge brackets. 5. Disconnect the electrical connections as follows:— White from terminal C(3). White from NC(2) Refer to FIGS. 27, 28. 2 red wires from terminal NO(4) 8.
SERVICING INSTRUCTIONS - Page 26 FIG. 31 FAULT FINDING CHART Publication No.
SHORT PARTS LIST - Page 27 KEY No.
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.
