Potterton PROFILE LPG 100e Installation And Servicing Instructions Download

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LPG 50e, 60e, 80e & 100e fanned

balanced flue gas fired boilers

THIS APPLIANCE IS FOR USE WITH PROPANE GAS ONLY

Installation and Servicing Instructions

LEAVE THESE INSTRUCTIONS ADJACENT TO THE APPLIANCE

Summary of Contents for PROFILE LPG 100e

Page 1: ...LPG 50e 60e 80e 100e fanned balanced flue gas fired boilers THIS APPLIANCE IS FOR USE WITH PROPANE GAS ONLY Installation and Servicing Instructions LEAVE THESE INSTRUCTIONS ADJACENT TO THE APPLIANCE ...

Page 2: ...flue system which provides a maximum flue length of 955mm 37in Vertical flue system which allows the flue to pass through a flat roof and terminate at a maximum height of 980mm 38in measured from the top of boiler case PRIMA LPG 50e 60e 80e Models only Standard horizontal flue system which is suitable for a wall thickness of 100mm 4in to 510mm 2Oin 2 metre horizontal flue system which provides a m...

Page 3: ...EGULATIONS BOILER DIMENSIONS Page 3 FIG 1 Boiler 50e 60e 80e 100e Dimension A 350 350 425 425 MM B 110 110 150 150 C 103 103 143 143 D 90 107 107 107 Flow Return 22mm 22mm 28mm 28mm Connections Copper Copper Copper Copper NOTE IF PIPEWORK IS TO BE RUN DOWN THE BACK OF THE BOILER THE NORMAL CLEARANCE OF 25mm BETWEEN THE REAR OF THE BOILER AND WALL CAN BE INCREASED TO 35mm IF DESIRED BY INVERTINGTHE...

Page 4: ...SITE REQUIREMENTS Page 4 FIG 2 GENERAL ARRANGEMENT ...

Page 5: ...n a compartment are given in BS 6798 1987 TABLE 1 PROFILE PRIMA AIR VENT AREAS in cm 50e 27 174 60e 33 213 80e 43 277 100e 54 349 If the openings draw air from outside the building the free areas may be halved Refer to BS 5440 Part 2 1976 for further guidance Balanced Flue Terminal and Ducting The fresh air inlet and flue ducts can be run from either the left right rear or top of the boiler to a m...

Page 6: ... supply to the boiler and its associated equipment should be controlled by a 3A fused double pole switch having at least 3mm contact separation in both poles so that complete isolation from the supply can be achieved to enable servicing work to be carried out in safety TECHNICAL DATA Page 6 Maximum working head 30 5m 100ft Minimum working head 150mm 6in Gas supply pressure 20 mbar Maximum flow tem...

Page 7: ...ON The resistance through the heat exchanger when operating with a water flow rate producing an 11 0C temperature rise at maximum boiler output are shown in TABLE 2 If other controls such as three position valves are used in the system the resistance through them quoted in their manufacturer s literature must be taken into account The pump may be fitted on either the flow or return and MUST be wir...

Page 8: ...em NOTE Although the system can be emptied using the drain off taps installed in the pipework around the system to empty the boiler it is necessary to remove the drain off cap positioned within the boiler case See FIG 2 SEALED SYSTEMS Installation The installation must comply with the requirements of BS 6798 1987 and BS 5449 Part 1 The B G publication British Gas Specification for Domestic Wet Cen...

Page 9: ...ake 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 or ii where access to a make up vessel would be difficult by using the mains top up method ...

Page 10: ...TECHNICAL DATA Page 10 FIG 7 FULLY PUMPED SEALED SYSTEM ...

Page 11: ...r position ensuring it is level the minimum side clearances are automatically allowed for REAR FLUING Mark holes A B D large flue outlet hole and side of boiler reference lines throught slots C SIDE FLUING Mark hole positions A D and side of boiler reference lines through Slots C Mark large flue outlet hole and holes B using the thick lines on the template for minimum clearance at the rear of the ...

Page 12: ...Slide rope sealing ring on to air duct 2 Engage the terminal on to the ends of the inner flue duct and outer air duct with its discharge vanes arranged to deflect the flue products in the desired direction Press terminal fully home 3 Engage four screws from accessory pack C into the pre drilled holes in the terminal and screw fully home These screws which are self drilling will pierce the air duct...

Page 13: ...let direction is required remove the appropriate flue outlet sealing plate and transfer it to the left hand position The boiler may now be lifted onto its mounting bracket or if desired the appliance liftweight can be further reduced by removing the fan fluehood assembly also the burner gas control assembly as follows 1 Removing fan fluehood assembly Disconnect the fan supply and earth leads from ...

Page 14: ...LER FIG 17 Rotate the left hand adjustment screw to align one of the holes in the base plate with hole D in the wall Working through the hole in the leg secure the base plate to the wall using the screw from accessory pack D Make good the wall surface around the flue terminal Fit optional terminal wall plate if required If the fan fluehood assembly or burner gas control assembly were removed to re...

Page 15: ...moved Reconnect flexible tubes to elbow ENSURE THEY ARE NOT KINKED The tubes are supplied at the length required for left hand flue outlet When using rear or right hand flue outlets to avoid kinking the tubes should be shortened by 150mm A band around the tube indicates the cutting point NOTE Red tube connects the front aluminium tube to the lower connection on the elbow each being identified with...

Page 16: ...tuated in the control box is not designed to accept wiring from all the on site controls and therefore the installer will usually need to incorporate a suitable junction box This may not be required if a Potterton Electronic Programmer is used as this incorporates a junction box The principle of wiring is shown in FIG 21 Further information on wiring of system controls can be found in the Control ...

Page 17: ...mp See NOTE Switched live from external controls to terminal marked MAINS SwL If there are no external controls fitted connect the SwL terminal to permanent live in the junction box NOTE Ensure that the earth conductor is longer than the L N SwL from the point of anchorage so that the current carrying conductors become taut before the earth conductor if cable is pulled out of the cable clamp When ...

Page 18: ...to the top hinge brackets and secure it with the lower two fixing screws First Lighting WARNING Before lighting the boiler ensure that the CASE DOOR HAS BEEN CORRECTLY FITTED and that the sealing strip fitted to the case door is forming a tight seal with the main boiler casing Before proceeding to light the boiler check that the external electricity supply to the boiler is switched off and that th...

Page 19: ...00 F 1800 F The thermostat has been calibrated by the makers and no attempt should be made to re calibrate it on site Turn the thermostat to the 0 position and check that the main burner shuts down Pump Over Run Thermostat Will keep the pump running after the boiler has shut down as long as the water temperature within the boiler is above 80 C The thermostat is preset and no adjustment is possible...

Page 20: ...COMMISSIONING Page 20 FIG 26 FUNCTIONAL FLOW DIAGRAM HONEYWELL FIG 27 BOILER WIRING DIAGRAM ...

Page 21: ...oiler and its controls but it should be remembered that attention must also be paid to the heating circuit itself including radiator valves thermostats the time control and the expansion and feed water system It is advisable to clean the boiler immediately after the end of the heating season In all cases prior to servicing light up the boiler and check that the pilot and main burners have a clean ...

Page 22: ...HEY ARE NOT KINKED NOTE Red tube connects front aluminium tube to the lower connection on elbow or adapter each being identified with a red ring E Reconnect the fan supply and earth leads 4 PILOT BURNER The following operations are only necessary if the pilot flame is distorted or the wrong size ie too small A Unscrew the pilot tube from the pilot assembly Take care B Unscrew the two hexagonal hea...

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Page 24: ...edure as detailed in the COMMISSIONING section of these instructions Page 18 MAIN BURNER 1 Switch off the external electricity supply by disconnecting the plug at the socket or switching off the external isolating switch 2 Remove controls cover case door and combustion chamber front panel as described in 1 Preparing the Boiler for Servicing operations A B and C 3 Remove the burner and gas control ...

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Page 26: ...ch connection identified with a red ring or adjacent red spot 6 Disconnect the three electrical leads white wire from terminal No 1 or NC orange from terminal No 2 or NO and brown from terminal No 3 or C Refer to FIGS 26 27 7 Replacement is the reverse of removal Ensure that the plastic tubes have the coiled springs positioned to prevent the tubes from kinking 8 Follow the full commissioning proce...

Page 27: ...lift door off the two upper hinge brackets 4 Remove three M4 nuts from sight glass retainer and remove sight glass assembly See above 5 Replacement is the reverse of removal Taking care that the clear circle in the sight glass lines up viewing hole in combustion chamber door NOTE new gaskets must be used when sight glass is fitted FAN 1 Switch off the external electricity supply by disconnecting t...

Page 28: ...Publication No 559472 01 92 SERVICING INSTRUCTIONS Page 26 FIG 30 FAULT FINDING CHART ...

Page 29: ...5 11 Gas Manifold O Ring 401637 12 Pump Over Run Thermostat K36 P2302 404507 13 Flue Elbow Sealing Gasket 225091 14 Electronic Control 407677 15 Fuse 1 amp T1A 907604 16 Thermostat Knob 213076 17 Pressure Switch Honeywell C6065A1192 642220 18 Fan Assembly SEL c w Gasket 909001 19 Overheat Thermostat LM7 P8503 404495 20 Main Burner Gasket 212085 21 2 2mm Injector Main Burner 50e Boiler 410971 2 4mm...

Page 30: ...ratory tract Precautions People with a history of skin complaints may be particularly susceptible to irritation High dust levels are only likely to arise following harsh abrasion In general normal handling and use will not present discomfort follow good hygiene practices wash hands before consuming food drinking or using the toilet First Aid Medical attention must be sought following eye contact o...

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Potterton PROFILE LPG 100e, Installation And Servicing Instructions

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