Potterton Profile Installation And Servicing Instructions Download

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Supplied By www.heating spares.co Tel. 0161 620 6677

lOOe, fanned balanced flue gas fired boiler

THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20) ONLY

Installation and Servicing Instructions

LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER

Summary of Contents for Profile

Page 1: ...ating spares co Tel 0161 620 6677 lOOe fanned balanced flue gas fired boiler THIS APPLIANCE IS FOR USE WITH NATURAL GAS G20 ONLY Installation and Servicing Instructions LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER ...

Page 2: ...ed on INDIRECT hot water systems only The cast iron heat exchanger 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 The boiler can be supplied with either of the following types of flue system these are packaged with the terminal and associated flue components 1 Standard Horizontal flue system Pa...

Page 3: ... British Standards and Codes of Practice B56798 B55440 Part 1 B55440 Part 2 B55449 Part1 BS5546 B54814 B56891 BUILDING REGULATIONS MODEL WATER BYELAWS BRITISH GAS PUBLICATION DM2 GAS SAFETY INSTALLATION AND USE REGULATIONS BUILDING STANDARDS SCOTLAND REGULATIONS BOILER DIMENSIONS Page 3 SITE REQUIREMENTS Page 3 The boiler is not suitable for external installation and should not be fitted directly ...

Page 4: ...Supplied By www heating spares co Tel 0161 620 6677 4 Site Requirements Page 4 FIG 2 GENERAL ARRANGEMENT ...

Page 5: ...a of 349 cm2 54 in2 Further details for installation of a boiler within a compartment are giving in BS 6798 If the openings draw air from outside the building the free areas may be halved Refer to BS 54401 Part 2 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 miniature terminal on the o...

Page 6: ...he 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 100 ft Power consumption 80 watts excluding pump Minimum working head on Fully Pumped systems...

Page 7: ...in the system the resistance through them quoted in their manufacturer s literature must be taken into account The pump may be fitted on either the flow or return and MUST be wired directly to the boiler terminal block see FIG 24 It must be fitted with two isolating valves which are positioned as close to the pump as possible Closing of any valve must always leave the open vent unobstructed TABLE ...

Page 8: ... over run thermostat This will ensure that the pump will continue to run after boiler shut down if the water temperature in the boiler is high If a three port diverter valve is used as shown in FIG 6 a by pass is not necessary since one circuit is always open temperature in the boiler is high thus preventing nuisance operation of the overheat thermostat If a three port diverter valve is used as sh...

Page 9: ...side of all heat emitters been made for the extension Where a vessel of the or calculated size is not available the next available larger size should be used The boiler flow temperature is ii where access to a make up vessel would be controlled at approximately 82ºC difficult by using the mains top up method or a remote automatic pressurisation and make up unit as sillustrated in FIG 7 METHODS 1 a...

Page 10: ...Supplied By www heating spares co Tel 0161 620 6677 10 Technical Data Page 10 Fig 7 Fig 8 ...

Page 11: ... in Separate Cartons Fig 9 TEMPLATE Place template in proposed boiler position ensuring it is level the minimum side clearances are automatically allowed for REAR FLUING Mark holes A B D age flue outlet hole and side of boiler reference lines through slots C SIDE FLUING Mark holes positions A D and side of boiler reference lines through slots C Extend Horizontal line from top of the boiler to side...

Page 12: ... Take air flue duct assembly and measuring from the flanged end mark and cut the outer air duct and inner flue duct to dimension Y plus 45 mm Ensure that both ducts are cut squarely NOTE Cutting length remains the same for minimum or maximum clearance at the rear of the boiler Fig 12 AIR FLUE DUCT ASSEMBLY 1 Slide rope sealing ring on to air duct 2 Engage the terminal on to the ends of the inner f...

Page 13: ...ver forward 10mm lower to release from the four side fixings and pull forward clear of the thermostat knob Remove door by undoing the two lower fixing screws and lift door off the two upper hinge brackets Remove the screws securing the combustion chamber front panel and remove panel Disconnect the fan supply leads from the connector adjacent to the fan Leaving in place the three screws identified ...

Page 14: ...and secure using four wing nuts accessory pack F Fig 17 SECURING BOILER 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 Fig 18 FLUE ELBOW...

Page 15: ... recommended A drain off tap should be installed close to the boiler if it is in a low point of the system On combined gravity hot water pumped central heating installations the flow and return pipes for both the gravity hot water circuit and pumped central heating circuit must be connected to tees fitted directly to the flow and return pipes on the boiler The gravity circuit should be installed i...

Page 16: ...ulb through grommet retaining hole then attach to return pipe using spring clip contained in auxiliary pack 5 Refit grommet ensuring that it makes a good seal around the capillary Ensure that the capillary is secure in clips provided Refer to Fig 2 6 ENSURE that the system change over switch in the control box is set in GRAVITY DHW position ELECTRICAL The boiler and all external control circuit wi...

Page 17: ...rnal gravity domestic hot water control circuit to terminal marked MAINS SwL Switched live from external pumped central heating control circuit to terminal marked MAINS L Neutral to terminal marked MAINS N Earth to terminal marked adjacent to cable clamp See NOTE If there are no external controls fitted connect the SwL and L terminals to permanent live in the junction box NOTE Ensure that the eart...

Page 18: ...two fixing screws Remove the temporary label from the front of the casing having checked compliance with the information it contains 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 ...

Page 19: ...y the makers and no attempt should be made to re calibrate it on site Turn on the boiler thermostat and ensure that the main burner is alight Turn the thermostat to the O position and check that the main burner shuts down Gravity Hot Water Pump Over Run Thermostat The function of this thermostat is determined by the position in which the GRAVITY FULLY PUMPED SYSTEM selection switch is set The ther...

Page 20: ...Supplied By www heating spares co Tel 0161 620 6677 20 Commissioning Page 20 Fig 27 FUNCTIONAL FLOW DIAGRAM Fig 28 BOILER WIRING DIAGRAM ...

Page 21: ...ain access to the flueways in the heat exchanger for cleaning The following notes apply to the boiler and its controls but it should be remembered that attention must also be paid to the heating circuit itself including radiator 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 case...

Page 22: ... adapter each being identified with a red ring 3 PILOT BURNER The following operations are only necessary if the pilot flame is distorted or the wrong size i e too small A Unscrew the steel pilot tube from the pilot assembly Take care not to damage the electrode B Unscrew the two hexagonal head screws securing the pilot and shield to the main burner and remove the pilot assembly be careful that th...

Page 23: ...sconnect the electrical supply from the gas valve Note White Rodgers has individual Wire positions Refer to FIGS 27 and 28 5 Unscrew the union connecting the pilot supply pipe to the gas control valve 6 Separate the gas control valve from the flange at the outlet port by removing the securing screws remove two M4 screws retaining valve support bracket unscrew gas inlet assembly at valve Note The S...

Page 24: ... 4 Disconnect six way plug two way plug and electrode lead from the electronic control Refer to FIGS 27 28 Disconnect the flying leads of the electronic control as follows white wires from the control thermostat brown wire from overheat thermostat blue wire from boiler terminal block connection N green yellow wire from earth post 5 Release the control by lifting it from the four retaining lugs 6 R...

Page 25: ...at bulb to the flow pipe 13 Remove the split grommet in the base of the boiler and the split grommet in the fan chamber Feed the capillary and bulb through the holes 14 Replacement is the reverse of removal The bulb of the new thermostat should be coated with heat conducting paste Ensure the rubber grommets in the base of the boiler and the fan chamber make a good seal around the capillary 15 Ensu...

Page 26: ...Supplied By www heating spares co Tel 0161 620 6677 26 Servicing Instructions Page 26 Fig 31 FAULT FINDING CHART ...

Page 27: ... Control Valve Kit White Rodgers 907702 382 988 10 Gas Control Valve Kit S I T 909029 289 396 11 Gas Manifold O Ring 401637 337 467 12 Gravity DHW Pump Over Run Thermostat CL8 P1510 404501 382 967 13 Flue Elbow Sealing Gasket 212084 337 424 14 Electronic Control 407677 382 462 15 Fuse 1 amp 641903 336 585 16 Thermostat Knob 225251 337 370 17 Pressure Switch 642216 385 887 18 Fan 409573 337 860 19 ...

Page 28: ...ritation Irritation to respiratory tract Precautions People with a history of skin complaints may be particularly susceptible to irritation High dust levels are only likely to arise following harsh abrasion In general normal handling and use will not present discomfort follow good hygiene practices wash hands before consuming food drinking or using the toilet First Aid Medical attention must be so...

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