Potterton Flamingo RS40 Installation And Service Manual Download Page 1

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Flamingo RS40 and RS50S balanced flue gas fired boiler

INSTALLATION & SERVICE GUIDE

Potterton Flamingo RS40
8.8 to 11.7 kW (30,000 to 40,000 Btu/hr) Output

Potterton Flamingo RS50S
11.7 to 14.7 kW (40,000 to 50,000 Btu/hr) Output

IMPORTANT

This appliance is toy use with Natural Gas only. It must be installed by a competent person as stated in the
Gas Safety (lnstallation and Use Regulations 1984. Leave these instructions adjacent to the gas meter.

Adjustable length, telescopic balanced flue terminal to suit 9 in. to 15 in. thick walls. A kit

(optional extra) is available to increase this to 24 ins.

Infill side panels (optional extra) are available for boilers mounted with exposed sides.

Case Extension Kit is provided (optional extra) to house a pump.

Page 1

Summary of Contents for Flamingo RS40

Page 1: ...l Gas only It must be installed by a competent person as stated in the Gas Safety lnstallation and Use Regulations 1984 Leave these instructions adjacent to the gas meter Adjustable length telescopic balanced flue terminal to suit 9 in to 15 in thick walls A kit optional extra is available to increase this to 24 ins Infill side panels optional extra are available for boilers mounted with exposed s...

Page 2: ...obloc casting which features two finned flueways and three waterways with two flow connections and two return connections The boiler thermostat phial is located in a pocket at the front upper left hand side of the heat exchanger A flue hood mounted on the top of the heat exchanger directs the flue gases through the boiler backplate into the balanced flue ducting from where gases are vented to atmo...

Page 3: ...a coil type of heat exchanger In a fully pumped system the primary pipework should include a lock shield valve 6 The circulating pump should be selected with reference to Figure 2 The resistance through the boiler heat exchanger will not exceed 20mbar 8in w g at a flow rate of 4 gall mm for RS40 boilers For RS50S boilers the heat exchanger resistance is considerably lower 7 The resistance through ...

Page 4: ...DATA SECTION Page 3 FIG 1 GENERAL ARRANGEMENT Flamingo RS40 illustrated Flamingo RS50S has a sectional heat exchanger Page 3 ...

Page 5: ... the outside wall of the building is important It should not be near any obstruction such as a balcony drain or stack pipe and it must not be sited near the corner of a building Where the terminal has to be positioned near an obstruction it is advisable to extend the terminal within its limits so that its grille clears the line of the obstruction when this is necessary a false wall should be built...

Page 6: ...FIG 2 PRESSURE LOSS ACROSS BOILER Page 4 DATA SECTION Page 5 ...

Page 7: ...rvicing Guide Users Guide Card NOTE Illustrated parts catalogues for these boilers are available to installers and servicing agents on request to Potterton International Limited Brooks House Coventry Road Warwick CV34 4LL GENERAL DATA Table 1 RS40 RS5OS Input 11 6 to 15 2kw 39 500 to 52 000 Btu h 15 6 to 19 2kW 53 000 to 65 500 Btu h Output into Water 8 8 to 11 7kW 30 000 to 40 000 Btu h 11 7 to 1...

Page 8: ...pes and meters for town gas Part 3 Low pressure installation pipes BS 5376 Selection and installation of gas space heating 1st and 2nd family gases Part 2 Boilers of rated input not exceeding 60kW BS 5449 Central heating for domestic premises Part 1 Forced circulation hot water systems CP 342 Centralized hot water supply Part 1 Individual dwellings Part 2 Buildings other than individual dwellings ...

Page 9: ...ing use a suitable sealing material and seal the gap between the duct and the inside of the hole in the wall ensure an airtight seal is obtained b Shamfer the plaster sealant as shown in Figure 4 to allow engagement of the balance flue terminal assembly which should then be pushed carefully up against the brickwork ensuring that the flanges on the wall plate slide over the duct retained in the wal...

Page 10: ...fittings are used FIG 4 MOUNTING FEATURES Flamingo RS4O illustrated Page 8 Installation Section Page 9 A Combined Gravity System RS5OS 1 Connect a suitable length of 28mm pipe with 90º elbow to either the R H or L H 1 B S P rear facing flow connections Hot water 2 Connect a suitable length of 22mm pipe with 90º elbow to the remaining 1 B S P rear facing flow connection Central heating 3 Connect a ...

Page 11: ...ossible Blank off the in B S P rear facing flow connection If it is necessary to use this in B S P flow connection a 22mm pipe should be connected to it and the 1in B S P connection used for the vent pipe NOTE The flow pipe must be turned through 90º and routed through the cut out in the back plate ensuring it is kept within the confines of the cut out It must not project above or to the side of t...

Page 12: ...d positions Zone valves which require an electrical supply to open them but not to close them should be wired in a similar manner but ignoring the closed connection from the room thermostat For this type of valve a room thermostat with a single pole contact should only be used Certain zone valves may require an additional connection to the auxilIary switch shown dotted This would apply to those va...

Page 13: ...FIG 6 BOILER WIRING DIAGRAM Page 10 Installation Section Page 11 FIG 7 GRAVITY HOT WATER WITH PUMPED CENTRAL HEATING ...

Page 14: ...FIG 8 GRAVITY HOT WATER WITH TEMPERATURE CONTROLLED AND PUMPED CENTRAL HEATING ...

Page 15: ... NOTE The minimum 900mm 3ft static head shown in figs 9 10 and 11 and mentioned in Section 1 in The System on page 2 can be reduced to 300mm 1ft providing the cold feed is connected directly into the spare return tapping on the boiler A static head of less than 300mm 1ft should not be used ...

Page 16: ...OTE These system diagrams figs 7 to 11 are schematic only Installers are recommended to read The System on page 2 and BS5376 and BS 5449 Part 1 FIG 10 FULLY PUMPED WITH ONE OR TWO TWO WAY VALVES Page 12 ...

Page 17: ...ight If resistance of earth is still greater than 1 937 ohm then this should be reported to your supervisor B Short Circuit Check appliance electrically disconnected all switches ON including stats a Meter set on 937 ohms x 1 scale Test leads from L to N in appliance terminal strip block if meter reads 0 then there is a short circuit b Meter set on 937 ohms x 100 scale Repeat test with leads from ...

Page 18: ...Page 13 ...

Page 19: ... Ensure that the system is full of water and that the pump and radiator isolating valves are open g Ensure that the time control if fitted is in an on condition and that the room and or cylinder thermostats where fitted are set to high temperatures h Turn the control button on the gas control valve clockwise as far as possible approximately 1 12th of a turn and release it This ensures the valve is...

Page 20: ...at the top adjacent to the locating tongue B Remove the thermostat knob then fit the controls cover in position and secure it with the captive screw Refit the thermostat knob NOTE The panel on the front of the controls cover through which the thermostat spindle and the control and igniter button protrude can be adjusted by a simple sliding action to line up with the controls 11 USER S GUIDE A user...

Page 21: ...t exchanger Tighten the two nuts Ensure hooks are engaged correctly d Remove the cloth covering the pilot burner assembly and clean any deposits from the pilot ignition electrode or thermocouple 4 MAIN BURNER ASSEMBLY REPLACEMENT Replace the main burner in position and secure it with the wingnut On the Flamingo RS50S boiler it will be necessary to slide the burner into the combustion chamber from ...

Page 22: ... 2 Switch off the main electricity supply to the boiler 3 Carry out operations A to C under 1 Preparing the Boiler 4 Unscrew the wingnut securing the main burner to the right hand side mounting bracket inside the combustion chamber On the Flamingo RS5OS boiler undo the screws securing the pilot plate to the burner Lift out the burner as described in taking care not to damage the pilot assembly or ...

Page 23: ... Test the boiler as described in 6 Final Adjustment e Honeywell Gas Control Valve 1 Turn off the boiler main gas cock 2 Switch off the main electricity supply to the boiler 3 Pull off the thermostat knob then unscrew the screw securing the controls cover to the boiler and slide off the cover 4 Remove the screw securing the cover over the electrical connections on the valve then remove the cover an...

Page 24: ...EW OF FLAMINGO COMPONENTS Flamingo RS4O illustrated Page 18 Service Section Page 19 they were connected for reconnecting to the new valve 5 Disconnect the pilot supply tube and the thermocouple connections from the valve ...

Page 25: ...hdraw the casing 5 Withdraw the thermostat phial from its pocket in the heat exchanger 6 Unscrew the backnut from around the spindle of the thermostat then remove the thermostat complete with its capillary Note the route of the capillary so the new capillary can be similarly routed 7 Disconnect the two electrical leads from the thermostat 8 Replacement is the reverse of removal Ensure that the the...

Page 26: ...nstruction for Gas Multi meter booklet CONDITION POSSIBLE CAUSE REMEDY 1 No gas supply Check all cocks are open in the supply to the boiler 2 Control button not pressed fully down Control button must be pressed fully down a Remove plastic electrical terminal cover from top of gas control valve by unscrewing the screw b Remove the four screws securing the solenoid valve to the top of the control va...

Page 27: ... Tighten thermocouple union nut finger tight plus turn only Ensure connection is clean and dry TOO MUCH PRESSURE MAY DAM AGE INSULATION AND CAUSE FAILURE 3 Pilot rate too low Adjust the pilot flame see Section 6 4 Partially blocked pilot filter or pilot injector As item A 3 and A 4 B Main burner fails to light and pilot is extinguished when pressure on the button is released 5 Failure of thermocou...

Page 28: ...ostat as detailed in Maintenance Instructions Section7 f 5 Blocked main burner injector Clean or replace injection as detailed in Maintenance Instructions Section 7 a 1 Thermostat out of calibration or faulty Remedy as in item C 4 D Main burner fails to shut down when water reaches predetermined temperature 2 Dirt on valve seat of Honeywell control Clean the valve seat as follows a Remove the sole...

Page 29: ...FIG 15 F F D AND THERMOCOUPLE Page 21 Service Section Page 22 FIG 16 SOLENOID VALVE ...

Page 30: ...232 98 Pilot Injector BCR 18 410209 390 794 71 75 Solenoid Operator 904750 396 693 70 74 Main Gas Valve 402803 393 659 90 103 Thermocouple Honeywell Q309A 402254 390 038 55 58 Thermostat Ranco C26 200996 382 291 107 114 Thermostat Knob 200277 357 634 85 90 Main Burner Injector Orifice 3 35mm dia 410909 56 59 lqniter Generator Vernitron 407623 387 951 92 Ignition Electrode 407635 101 Ignition Elect...

Page 31: ...Back page Page 23 ...

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