You can rely on

Installation & Service Instructions Precision

Condensing
Central Heating
Boiler

Precision

www.britishgas.co.uk

HomeCare® 0800 048 1000

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.
 Building Regulations and the Benchmark Commissioning
Natural Gas Checklist
British Gas Potterton Precision
G.C.No 41 - 592 - 33 Building Regulations (England & Wales) require notification of
the installation of a heating appliance to the relevant Local
Authority Building Control Department. This can be achieved
via a Competent Persons Self Certification Scheme as an
option to notifying the Local Authority directly.

The Health & Safety Executive operates the ‘Gas Safe Register’,
a self-certification scheme for gas heating appliances.

These arrangements represent a change from the situation

whereby compliance with Building Regulations was accepted as
being demonstrated by completion of the Benchmark Logbook
(which was then left on site with the customer).

With the introduction of Self Certification Schemes, the

Benchmark Logbook is being withdrawn. However, a similar
document in the form of a commissioning checklist and service
interval record is incorporated at the back of these instructions.

This company is a member of the Benchmark initiative and fully

supports the aims of the programme. Its aim is to improve the
standards of installation and commissioning of central heating
systems in the UK and to encourage the regular servicing of all
central heating systems to ensure safety and efficiency.

Building Regulations require that installations should comply

with manufacturer's instructions. It is therefore important that
the commissioning checklist is completed by the installer. The
relevant section of Building Regulations only relates to
dwellings. Therefore the checklist only applies if the appliance is
being installed in a dwelling or some related structure.

The flowchart opposite gives guidance for installers on the

process necessary to ensure compliance with Building
Regulations.

The Benchmark Scheme

Benchmark places responsibilities on both manufacturers and installers. The

purpose is to ensure that customers are provided with the correct equipment for
their needs, that it is installed, commissioned and serviced in accordance with the
manufacturer’s instructions by competent persons and that it meets the
requirements of the appropriate Building Regulations. The Benchmark Checklist
can be used to demonstrate compliance with Building Regulations and should be
provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work
in accordance with the Benchmark Code of Practice which is available from the
Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.uk for more information.

0086
ISO 9001
FM 00866

2
 Installer Notification Guidelines

Choose Building
Regulations Notification
Route

Competent Person's Building Control

Self Certification Scheme

Install and Commission this Contact your relevant Local

appliance to manufacturer's Authority Building Control
instructions (LABC) who will arrange
an inspection or contact
a government approved
inspector
Complete the
Benchmark Checklist

If you notify via the ‘Gas Safe

Register’, the register will issue
the Building Regulations Install and Commission this
certificate on members’ behalf appliance to manufacturer's
instructions

Scheme Members only

Call ‘Gas Safe Register’ on: Complete the

0800 408 5577 Benchmark Checklist
or log onto:
www.gassaferegister.co.uk
within 10 days

You must ensure that the

certificate number issued by
the ‘Gas Safe Register’ is written
onto the Benchmark Checklist

‘Gas Safe Register’ will issue a

Building Regulations Compliance LABC will record the data
Certificate to the property owner and will issue a
and inform the relevant LABC certificate of compliance

3
 Legislation

IMPORTANT - Installation, Commissioning, Service & Repair This company declares that no substances harmful
to health are contained in the appliance or used
This appliance must be installed in accordance with the manufacturer’s instructions and during appliance manufacture.
the regulations in force. Read the instructions fully before installing or using the
appliance. The appliance is suitable only for installation in GB and IE
and should be installed in accordance with the rules in
In GB, this must be carried out by a competent person as stated in the Gas Safety force, and only used in a suitably ventilated location.
(Installation & Use) Regulations.
In GB, the installation must be carried out by a Gas Safe
Registered Installer. It must be carried out in accordance
Definition of competence: A person who works for a Gas Safe registered company with the relevant requirements of the:
and holding current certificates in the relevant ACS modules, is deemed competent. • Gas Safety (Installation & Use) Regulations.
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic
Regulations (Northern Ireland).
Gas Installations”. • The Water Fittings Regulations or Water Byelaws in
Scotland.
NOTE: The addition of anything that may interfere with the normal operation of the • The Current I.E.E. Wiring Regulations.
appliance without express written permission from the manufacturer or his agent could
Where no specific instructions are given, reference should
invalidate the appliance warranty. In GB this could also infringe the Gas Safety
be made to the relevant British Standard Code of Practice.
(Installation and Use) Regulations.
In IE, the installation must be carried out by a competent
Warning - Check the information on the data plate is compatible with local supply Person and installed in accordance with the current edition
conditions. of I.S. 813 ‘Domestic Gas Installations’, the current Building
Regulations and reference should be made to the current
ETCI rules for electrical installation.

All systems must be thoroughly flushed and treated

All Gas Safe registered engineers carry an ID card with their licence number and a with inhibitor (see section 6.2).
photograph. You can check your engineer is registered by telephoning
0800 408 5500 or online at www.gassaferegister.co.uk

The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)
Codes of Practice, most recent version should be used
Regulations 1993 No 3083” and is deemed to meet the requirements of Directive
92/42/EEC on the energy efficiency requirements for new hot water boilers fired with
In GB the following Codes of Practice apply:
liquid or gaseous fuels:- Standard Scope
BS 6891 Gas Installation.
BS 5546 Installation of hot water supplies for domestic
Type test for purpose of Regulation 5 certified by: purposes.
Notified Body 0087. BS EN 12828 Heating systems in buildings.
BS EN 14336 Installation & commissioning of water based
heating systems.
Product/Production certified by: BS 6798 Installation of gas fired hot water boilers.
BS 5440 Part 1 Flues.
Notified Body 0086. BS 5440 Part 2 Ventilation.
BS 7074 Expansion vessels and ancillary equipment for
sealed water systems.
For GB/IE only. BS 7593 Treatment of water in domestic hot water
central heating systems.

In IE the following Codes of Practice apply:

Standard Scope
I.S. 813 Domestic Gas Installations.
The following BS standards give valuable additional information;
BS 5546 Installation of hot water supplies for domestic
purposes.
BS EN 12828 Heating systems in buildings.
BS EN 14336 Installation & commissioning of water based
heating systems.
BS 7074 Expansion vessels and ancillary equipment for
sealed water systems.
BS 7593 Treatment of water in domestic hot water
central heating systems.

4
 Safe Manual Handling

General

The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.

Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and
hands. Health & Safety is the responsibility of EVERYONE.

There is no ‘safe’ limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.

Do not handle or lift unless you feel physically able.

Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.

Preparation

Co-ordinate movements - know where, and when, you are both going.

Minimise the number of times needed to move the boiler - plan ahead.

Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special
care on ladders/into lofts.

Technique

When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards and
sideways and keep the load as close to your body as possible.

Where possible transport the boiler using a sack truck or other suitable trolley.

Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary.
See section 8.3 of these instructions for recommended lift points.

Remember

The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.

If at any time when installing the boiler you feel that you may have injured yourself STOP !!
DO NOT ‘work through’ the pain - you may cause further injury.

IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!

5
 Contents
Section Page

1.0 Introduction 7

2.0 General Layout 8

3.0 Appliance Operation 9

4.0 Technical Data 10

5.0 Dimensions and Fixings 11

6.0 System Details 12

7.0 Site Requirements 16

8.0 Flue Options 21

9.0 Plume Displacement 26

10.0 Installation 30

11.0 Electrical 36

12.0 Commissioning the Boiler 38

13.0 Fitting the Outer Case 41

14.0 Servicing the Boiler 42

15.0 Changing Components 45

16.0 Short Parts List 51

17.0 Fault Finding 52

Benchmark Checklist 58

6
 1.0 Introduction

1.1 Description

1. The British Gas Potterton Precision is a gas fired room

sealed fan assisted condensing central heating boiler.

2. The maximum output of the British Gas Potterton Precision

is adjustable at the time of commissioning (Section 12.0). There
are 5 outputs, set by turning the Output Selector to the
appropriate position (see item 17 on the General Layout
diagram, Section 2.0, for its location).

3. The boiler automatically adjusts the output up to the

selected maximum according to the system load. It is designed
for use on Natural Gas (G20) only and is factory set at an
Bri
tish
Ga
s output of 19.27kW (condensing).

4. The boiler is suitable for fully pumped open vented central

heating and domestic hot water systems and sealed systems.
Fig. 1
5. A label giving details of the model, serial number and Gas
Council number is situated on the rear of the lower door panel
Lower Door Panel (Fig. 1).
Position of Label

6. The boiler data badge is positioned on the air box door

(Fig. 2).

7. The boiler is intended to be installed in residential / domestic

environments on a governed meter supply only.

8. The boiler must be installed with one of the purpose

designed flues such as the standard horizontal flue kit, part no
236921.
Output Setting
Procedure Instruction
1.2 Important Information

Man-made mineral fibre

• Some component parts of this appliance (insulation pads,
Air Box Door
gaskets and rope seals) are manufactured from man-made
mineral fibre.
• Prolonged or excessive exposure to this material may result
in some irritation to the eyes, skin or respiratory tract.
• It is advisable to wear gloves when handling these items.
• Irritant dust will only be released from the items if they are
Fig. 2
broken up or subjected to severe abrasion. In these instances a
suitable dust mask and goggles should be worn.
Data Badge • Always thoroughly wash hands after installation, servicing or
changing components.
• When disposing of any items manufactured from man-made
mineral fibre care must be exercised.
• If any irritation of the eyes or severe irritation of the skin is
experienced seek medical attention.

1.3 Contents of Pack

The pack contains:-

• Boiler
• Wall Plate
• Template & ‘Quick Fit’ Guide
• Literature Pack
• Fittings Pack

7
 2.0 General Layout

2.1 Layout (Figs. 3,4,5 & 6)

16

1. Wall Plate
2. Flue Elbow
3. Heat Exchanger
4. Burner
5. Air Box
6. Fan Protection Thermostat

Fig. 5 7. Fan Assembly

15 14 8. Condensate Trap
2 9. PCB Housing Assembly
10. Gas Tap
11. Gas / Air Ratio Valve
12. Flow Pipe Connection
1
13. Return Pipe Connection
14. Flow Temperature Safety Thermostat - Black
15. Flow Temperature Thermistor - Red
3
16. Flow Switch (dry fire protection)

13 17. Output Selector Switch Cover

12

4 17

Fig. 3
7

11

Fig. 4 Fig. 6
10

8
 Mains On.
3.0 Appliance Operation

3.1
Flow NO
temperature less
than set point ?
1. Switched Live On: When the switched live switches
on if the flow temperature is less than the set point
then pump overrun occurs. When the switched live
YES switches on if the flow temperature is greater than the
set point then pump overrun occurs.
10 second
Pump On.
2. Pump On: The pump is on while the fan, spark
generator and gas valve are off. After 10 seconds if the
flow switch has made then fan pre-purge occurs. After
10 seconds if the flow switch has not made then anti-
NO
Flow switch made ? cycle occurs.

3. Fan Pre-Purge: The pump and fan are on while the

spark generator and gas valve are off. After 5 seconds
YES
ignition occurs.
YES Ignition done
5 second
and less than 5
Fan Pre-Purge. 4. Ignition: The pump, fan, spark generator and gas
attempts made ?
valve are on. If a flame is detected then burner on
occurs. If a flame is not detected within 5 seconds and
less than 5 ignition attempts have been made then fan
purge occurs. If a flame is not detected within 5
5 second seconds and 5 ignition attempts have been made then
Ignition Period. ignition lockout occurs.

5. Burner On: The pump, fan and gas valve are on

while the spark generator is off. Flow temperature is
controlled by varying the fan speed (and thereby the
Flame Detected ? Ignition done and
gas rate) to achieve optimum operation. If the flow
5 attempts made ?
temperature is greater than the set point or the TRVs
all shut down then fan post purge occurs.
YES
Burner On. 6. Fan Post Purge: The pump and fan are on while the
YES spark generator and gas valve are off. After 5 seconds if
the TRVs are not shut down then pump overrun
occurs. After 5 seconds if the TRVs are shut down then
All TRVs anti-cycle occurs.
Ignition
shut or Flow temperature
greater than set point ? Lockout.
7. Pump Overrun: The pump is on while the fan, spark
generator and gas valve are off. After 1 minute anti-
YES cycle occurs.

5 second
8. Anti-cycle: The pump, fan, spark generator and gas
Fan Post Purge.
valve are off. After 3 minutes if the flow temperature is
less than the set point then pump on occurs. After 3
minutes if the flow temperature is greater than the set
point then pump overrun occurs.
YES All TRVs
shut down ?
9. Ignition Lockout: The pump, fan, spark generator
and gas valve are off. The boiler can only be reset by
manually using the reset button.
NO

1 minute
Pump Overrun.

3 minute
Anti-cycle.

9
 4.0 Technical Data

Appliance Type C13 C33 C53 Max Gas Rate (2H - G20 - 20mbar) Electrical Supply 230V~ 50Hz
(After 10 Mins) (Appliance must be connected to an
Appliance Category CAT I 2H Setting 1 2 3 4 5 earthed supply)
m3/hr 1.34 1.64 1.94 2.31 2.95
Heat Input (Q)(Gross) Max Min Power Consumption 80W
Setting 1 kW 13.34 10.2 Injector (Natural Gas)
6.5mm Diameter External Fuse Rating 3A
Setting 2 kW 16.88 10.2
Setting 3 kW 20.18 10.2 Nox Class 5
Internal Fuse Rating (BS 4265)
Setting 4 kW 24.50 10.2 Horizontal Fuse 3.15 AT (PCB)
Setting 5 kW 33.76 10.2 Flue Terminal Diameter 110mm
Dimensions Projection 150mm Electrical Protection IPX2
Heat Output (P)
Connections
(Non Condensing 70° C Mean Water Temp) Water Content
Max Min Gas Supply - 1
/2in BSPT
Central Heating Flow - 22mm litres 2.6
Setting 1 kW 11.82 9.14 Central Heating Return - 22mm pints 4.6
Setting 2 kW 15.24 9.14 Condensate Drain - 1 in BSP
Static Head
Setting 3 kW 17.81 9.14
Outercase Dimensions max 30 metres (100 ft)
Setting 4 kW 22.00 9.14 Overall Height Inc Flue Elbow - 750mm min 1 metre (3.25 ft)
Setting 5 kW 30.18 9.14 Casing Height - 600mm
Casing Width - 390mm Low Head 0.2m (8 in) min
Heat Output (P) Casing Depth - 280mm
(Condensing 40° C Mean Water Temp) System Detail
Max Min Clearances fully pumped open vented & sealed systems
(For unventilated compartments see Section 7.2)
Setting 1 kW 12.81 10.1 Gas Connection
Setting 2 kW 16.49 10.1 Both Sides 5mm Min G1/2” B.S.P. Thread
Above Casing 200mm Min
Setting 3 kW 19.27 10.1
Below Casing 50mm Min Controls
Setting 4 kW 23.8 10.1 Front (For Servicing) 500mm Min boiler thermostat, safety thermostat,
Setting 5 kW 32.61 10.1 Front (In Operation) 5mm Min flow switch, electronic flame sensing,
temperature protection thermostat &
Weights kg condensate blockage sensor
NOTE: The boiler is delivered at Setting 3.
Packaged Boiler Carton 36.2
If a greater or lesser output is required
Packaged Flue Kit 3.6
refer to the output setting procedure on Inlet Pressure at Gas Valve (Natural Gas)
Installation Lift Weight 26.0
the boiler front panel. The electrical supply Min 18.1 mbar
MUST BE ISOLATED before doing this, CO/CO2 Ratio Up to a maximum Max 22.5 mbar
and it must only be done by a competent of 0.004
registered person. (see Section 12.1)
CO2 Level 9% ± 1%
Flow Temperature (adjustable)
SEDBUK Declaration 55° C to 78° C (± 5° C)
Setting 1 - The efficiency is 90.5% Recommended System
NOTE: All data in this section are nominal values
Setting 2 - The efficiency is 91.3% and subject to normal production tolerances Temperature Drop
Setting 3 - The efficiency is 90.4% Condensing 20°C 36°F
Setting 4 - The efficiency is 90.9%
Setting 5 - The efficiency is 90.9%
Hydraulic Resistance Chart
This value is used in the UK Government’s Standard
220 91
Assessment Procedure (SAP) for energy rating of
200 83
Pressure Drop (mbar)

Pressure Drop (in wg)

dwellings. The test data from which it has been

180 75
calculated has been certified by 0087.
160 66
140 58
120 50
100 42
80 33
60 25
40 17
20 8

0 10 20 30 40
Water Flow Rate (litres/min)

10
 5.0 Dimensions and Fixings

DIMENSIONS

E A 600mm
At Least 1.5°
B 280mm

C 390mm
A
D 150mm Ø Min.

E 162.5mm

F 96mm
B

360° Orientation

D C
The 1.5° fall provided by the elbow
is to allow condensate to run back to
the boiler, for disposal through the
Tube Ø 110mm condensate discharge pipe.

Fig. 7

SIDE FLUE (left and right)

X
For every 1m of horizontal flue
At Least 1.5° length, the clearance above the top
of the flue elbow should be 27.5mm
to incorporate the 1.5° fall in the flue
from the terminal to the elbow.

Flue length (Y) Clearance (X)

up to 1m 27.5mm
1m - 2m 55mm
2m - 3m 82.5mm
Fig. 8

11
 6.0 System Details

6.1 Water Circulating Systems

1. The appliance is suitable for use with open vent fully

pumped systems and sealed systems .
The following conditions should be observed on all
systems:
• The static head must not exceed 30m (100ft) of water.
• The boiler must not be used with a direct cylinder.
• Drain cocks should be fitted to all system low points.
• All gas and water pipes and electrical wiring must be
installed in a way which would not restrict the servicing
of the boiler.
• Position isolating valves as close to circulating pump as
possible.
• It is recommended that the return pipe is fitted with an
automatic air vent as close to the boiler as is practical.

6.2 Treatment of Water Circulating Systems

• All recirculatory water systems will be subject to

corrosion unless an appropriate water treatment is
applied. This means that the efficiency of the system will
deteriorate as corrosion sludge accumulates within the
system, risking damage to pump and valves, boiler noise
and circulation problems.

• When fitting new systems flux will be evident within the

system, which can lead to damage of system components.

• All systems must be thoroughly drained and flushed out

using, for example, Sentinel X300 or X400 or Fernox F3.
They should be used following the flushing agent
manufacturer’s instructions.

• System additives - corrosion inhibitors and flushing

agents/descalers should comply to BS7593 requirements,
e.g. Sentinel X100 and Fernox MB-1 which should be used
following the inhibitor manufacturer’s instructions.

• Full instructions are supplied with the products, for

further information contact Sentinel (0800 389 4670) or
Fernox (0870 870 0362)

Failure to flush and add inhibitor to the system will

invalidate the appliance warranty.

• It is important to check the inhibitor concentration after

installation, system modification and at every service in
accordance with the manufacturer’s instructions. (Test kits
are available from inhibitor stockists.)

• For information or advice regarding any of the above

contact Technical Enquiries.

12
 Copper 6.0 System Details
Copper 0.5m
0.5m
Flow
Boiler 6.3 Pipework
Return
Copper
1. The sizes of flow and return pipes from the boiler should
1m
be determined by normal methods, according to the
Fig. 9 requirements of the system. The connections on the boiler
are 22mm.

mm 2. A 20 °C (36°F) drop in temperature across the system is

500 22mm
recommended for condensing boilers. Existing radiators may
Open Vent
45° be oversized and so allow this, but where radiator sizing is
marginal it may be advisable to retain a system temperature
drop of 11°C (20°F).
1000mm
15mm
Min 400mm
Cold
Min Head NOTE: When Output Setting 5 is selected 28mm pipe
Feed
should be used to connect to the boiler flow and return.

150mm 3. In systems using non-metallic pipework it is necessary to

Max use copper pipe for the boiler Flow and Return. The copper
Boiler must extend at least 1 metre from the boiler and include any
Pump
branches (Fig. 9).
Flow

Return
6.4 Low Head Installation

Fig. 10 Typical Low Head Installation

1. Using a close couple arrangement the minimum head is as
shown in the diagrams (Figs. 10 & 11) subject to the
following conditions:
mm 22mm
500 a) The pump being adjusted to give a 20°C drop across
Open Vent
45° the boiler.
b) The pump must be fitted on the flow.
c) The pump must be fitted in accordance with the
Automatic Air
pump manufacturer's instructions.
Vent 15mm 400mm d) The open vent pipe must be taken up from a tee in a
1000mm Cold Min Head horizontal section of the flow pipe.
Min Feed
Boiler An alternative Low Head Installation (Fig. 12)
150mm
Max
2. For heads below 400mm then a combined vent and feed
Pump pipe may be connected. This must be a minimum of 22mm
Flow diameter. It is recommended that an air separator is fitted
Return
when using a combined feed and vent pipe.

6.5 Pump
Fig. 11 If Conditions Require,
This System Possible 1. Providing that the cold feed and open vent pipe are
positioned correctly (e.g. the system is not prone to
pumping over, air entrainment etc.) the pump may be fitted
22mm
200mm on the primary return pipe.
Feed & Vent
Min Pipe

Air
Separator

Boiler Pump

Flow

Return

Fig. 12
Alternative Low Head Installation

13
 230V Key to colours
50Hz b - Blue
L N E
g/y
b Y Plan
br - Brown
6.0 System Details
w Diverter
Cylinder Valve w - White
Stat gr
o - Orange
1
6.6 System Controls
Room
o gr - Grey
Stat g/y - Green/Yellow
C 2 This boiler does not require a bypass.
Boiler This boiler does not require a permanent live.
L E N P/F The pump only needs wiring directly to the boiler for
fully TRV’d systems.

Timer IMPORTANT: When output is at setting 5 (see

L Section 12.1) the pump cannot be wired directly to
N
CH on NE L Pump the boiler. Only use wiring diagrams i & ii opposite
HW on when set to 5.
HW off

i) Y Plan, Room Thermostat System, CH Interlocked By Room Thermostat 1. To comply with Part L1 of the Building Regulations the
At least the Radiator(s) near the Room Thermostat not TRV’d heating system into which the boiler is installed should
Pump run from Switched Live include the following:
By-pass permitted but not required for Part L1 compliance
a) zone controls
gr b) timing controls
230V b
c) boiler control interlocks
gr
50Hz
L N E Motor Motor
b br 2. Such a system needs to be fully pumped and must
provide independent temperature and time control to
br S Plan o g/y S Plan
g/y Valve Valve both the heating and hot water circuits and have a boiler
Room Cylinder o interlock.
Stat Stat
3. The boiler should be controlled so that it operates on
Boiler
L E N P/F
demand only. Where it is proposed to effect control by
thermostatic radiator valves, a room thermostat (or
other device such as a flow switch - a flow switch is
Timer integral to this boiler) should also be provided to switch
L off the boiler when there is no demand for heating or
N
Pump hot water.
CH on NE L
HW on
4. The interlock for the CH circuit can be provided by
ii) S Plan, Room Thermostat System, CH Interlocked By Room Thermostat either a Room Thermostat or a fully TRV’d system with
At least the Radiator(s) near the Room Thermostat not TRV’d the pump wired back to the boiler without a bypass.
Pump run from Switched Live
By-pass permitted but not required for Part L1 compliance
Connection diagrams for both options for Y and S plan
systems are shown.

230V
50Hz gr
L N E b Y Plan 230V b
gr
g/y
w Diverter 50Hz
L N E
Cylinder Valve b
Motor Motor
gr br
Stat
1 o S Plan o g/y S Plan
g/y Valve Valve
C 2 br Cylinder o
Stat
Boiler
L E N P/F
Boiler
L E N P/F

Timer
L Timer
N
CH on NE L Pump L
HW on N
CH on NE L Pump
HW off
HW on

iii) Y Plan, Fully TRV’d System, CH Interlocked By Boiler Flow Switch

Room Thermostat should not be fitted iv) S Plan, Fully TRV’d System, CH Interlocked By Boiler Flow Switch
Pump must be run from Boiler P/F connection for Part L1 compliance Room Thermostat should not be fitted
By-pass not permitted (must be valved off) for Part L1 compliance Pump must be run from Boiler P/F connection for Part L1 compliance
By-pass not permitted (must be valved off) for Part L1 compliance

14
 6.0 System Details
3 Litre
Top Up Bottle
Air
Vent
(if required) 6.7 Sealed Systems (Fig. 13)

1. SAFETY VALVE - A safety valve complying with the

Filling requirements of BS 6750 Part 1 must be fitted close to
Pressure Point the boiler on the flow pipe by means of a horizontal or
Safety Gauge vertically upward connection with no intervening valve
Valve
or restrictions and should be positioned to facilitate
Pump
testing. The valve should be pre-set and non-adjustable
to operate at a pressure of 3 bar (45 Ibf/in2). It must be
arranged to discharge any water or steam through a pipe
Expansion Radiator to a safe outlet position.
Vessel Circuit
Boiler 2. PRESSURE GAUGE - A pressure gauge of minimum
range 0-4 bar (0-60 Ibf/in2) with a fill pressure indicator
System Drains at must be fitted to the system, preferably at the same
Low Point point as the expansion vessel in an easily visible position.
Max Boiler Flow 3. EXPANSION VESSEL - An expansion vessel
Fig. 13 Temp = 82° C complying with the requirements of BS 4814 must be
fitted to the system by means of a connection close to
the inlet side of the circulating pump in accordance with
Method of determining minimum valve of
expansion vessel volume for sealed systems the manufacturers instructions, the connecting pipe being
using Potterton Boilers unrestricted and not less than 15mm (1/2 in) nominal size.
The volume of the vessel should be suitable for the
system water content and the nitrogen or air charge
Multiply Total pressure should not be less than the system static head
Vessel Charge Initial System Water Content Of (See Table. 1).
Pressure (Bar) Pressure (Bar) System By (Litres)
Further details of sealed system design can be obtained
from BS 5449 and the British Gas publication entitled
0.5 0.067 'Specifications for Domestic Wet Central Heating
1.0 0.112 Systems'.
0.5
1.5 0.207
2.0 0.441 4. FILLING POINT - A filling point connection on the
central heating return pipework must be provided to
facilitate initial filling and pressurising and also any
1.0 0.087
1.0 subsequent water loss replacement / refilling. The sealed
1.5 0.152 primary circuits may be filled or replenished by means of
2.0 0.330 a temporary connection between the primary circuit and
a supply pipe provided a ‘Listed’ double check valve or
1.5 0.125 some other no less effective backflow prevention device
1.5
2.0 0.265 is permanently connected at the inlet to the circuit and
the temporary connection is removed after use. The
filling method adopted must be in accordance with all
Example :- System Volume = 75 litres
Table. 1 relevant water supply regulations and use approved
Vessel Charge Pressure = 1.0 bar
equipment.
Initial System Pressure = 1.5 bar
Your attention is drawn to, for GB: Guidance G24.2 and
Then :- 75 x 0.152 = 11.4 litres
Expansion Vessel Volume recommendation R24.2 of the Water Regulations Guide.
for IE: the current edition of I.S. 813 “Domestic Gas
NOTE Installations”.
Where a vessel of the calculated size is not obtainable then
the next available larger size should be used. 5. MAKE UP SYSTEM - A method of replacing water
lost from the system should be provided either by
means of a make up vessel of not more than 3 litres (5
pints) capacity, mounted above the highest point of the
system, or by re-pressurisation of the system.

6. VENTING - A method of venting the system during

filling and commissioning must be provided by fitting
automatic air vents or by venting manually.
Double
Stop Check Stop 7. HOT WATER STORAGE - The hot water storage
Valve Valve Valve vessel must be of the indirect coil type. All components
used in the system must be suitable for operation at
110°C (230°F) and at the pressure allowed by the safety
valve.

Temporary
Cold CH
Hose
Mains Return
Fig. 14
Inlet
15
 7.0 Site Requirements

7.1 Location

NOTE: Due to the high efficiency of the boiler a

plume of water vapour will be discharged from the
flue. This should be taken into account when siting
the flue terminal.

1. The boiler may be fitted to any suitable wall with the

flue passing through an outside wall or roof and
Zone 2
discharging to atmosphere in a position permitting
satisfactory removal of combustion products and
Window
Recess providing an adequate air supply. The boiler should be
Zone 1 fitted within the building unless otherwise protected by a
suitable enclosure i.e. garage or outhouse. (The boiler
Zone 2
may be fitted inside a cupboard - see Section 7.2).

Zone 0
2. If the boiler is sited in an unheated enclosure then it is
recommended to incorporate an appropriate device for
0.6 m
frost protection in the system controls.
Window
Recess
3. If the boiler is fitted in a room containing a bath or
Zone 2
shower it MUST NOT BE fitted in zone 0, 1 or 2, ONLY
within the shaded area (Figs. A & B shows zone
dimensions for a bathtub. For other examples refer to
the Current I.E.E. Wiring Regulations) reference must be
Fig. A made to the relevant requirements.
In GB Only
In GB this is the current I.E.E. Wiring Regulations and
Building Regulations.
In IE reference should be made to the current edition of
I.S. 813 “Domestic Gas Installations” and the current
ETCI rules.

Ceiling 4. If the boiler is to be fitted into a building of timber

Window Recess frame construction then reference must be made to the
Zone 2
Outside Zones current edition of Institute of Gas Engineers Publication
IGE/UP/7 (Gas Installations in Timber Framed Housing).

7.2 Ventilation of Compartments

2.25 m
Zone 1 Zone 2 1. Where the boiler is installed in a cupboard or
compartment, no air vents are required for cooling
purposes providing that the minimum dimensions below
Zone 0 are maintained.
Sides 15mm
Top 200mm
0.6 m
Bottom 50mm
Front 30mm

Fig. B 2. If the boiler is installed in a smaller cupboard or

In GB Only
compartment it must be ventilated according to
BS 5440 Part 2 and the minimum clearances given in
section 4.0 “Technical Data” maintained.

3. Any compartment should be large enough to house

the boiler only.

NOTE: The ventilation label on the front of the outer

case MUST NOT BE REMOVED when the appliance is
installed in a compartment or cupboard.

16
 5mm Min 390mm 5mm Min
7.0 Site Requirements

7.3 Clearances (Figs. 15 &16)

200mm
1. A flat vertical area is required for the installation of the
boiler.

2. These dimensions include the necessary clearances

around the boiler for case removal, spanner access and air
movement. Additional clearances may be required for the
passage of pipes around local obstructions such as joists
running parallel to the front face of the boiler.
600mm
3. For unventilated compartments see Section 7.2.

7.4 Gas Supply

1. The gas installation should be sized and installed in

accordance with the relevant standard to match the
Precision

output setting of the boiler. In GB this is BS 6891. In IE this

is the current edition of I.S. 813 “Domestic Gas
Installations”.
Fig. 15 50mm
2. The connection to the appliance is a 1/2in BSPF.

3. Ensure that the pipework from the meter to the

appliance is of adequate size to ensure correct operation.
Do not use pipes of a smaller diameter than the boiler
gas connection.

7.5 Electrical Supply

At Least 1.5°
1. External wiring must be correctly earthed, polarised and
in accordance with relevant regulations/rules. In GB this is
the current I.E.E. Wiring Regulations. In IE reference
should be made to the current edition of ETCI rules.

2. The mains supply is 230V ~ 50Hz fused at 3A.

500mm

For Servicing NOTE: “The method of connection to the electricity

Purposes supply must facilitate complete electrical isolation of the
appliance”.

Note! There is no method of isolating the boiler, at the

user interface.

Connection may be via a fused double-pole isolator with a

contact separation of at least 3mm in all poles and servicing
the boiler and system controls only.

WARNING: The PCB Control and Fan

280mm Assembly are 325 Vdc. Isolate at supply
5mm
before access.
In Operation
Fig. 16

17
Examples are shown of the following methods of termination:-
i) to an internal soil & vent pipe
ii) via an internal discharge branch (e.g. sink waste) downstream of the trap 7.0 Site Requirements
iii) to a drain or gully
iv) to a purpose made soakaway
v) pumped into an internal discharge branch (e.g. sink waste) downstream of the trap 7.6 Condensate Drain
vi) pumped into an external soil & vent pipe
vii) to a drain or gully with extended external run & trace heating FAILURE TO INSTALL THE CONDENSATE DISCHARGE
PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE
OPERATION OF THE BOILER.
It is strongly recommended to discharge internally into the household
drainage system. If connecting to a rain water drain, that drain MUST CAREFUL CONSIDERATION MUST BE GIVEN TO THE
discharge into a foul drain. POSSIBILITY OF THE PIPEWORK BEING SUBJECT TO
21.5mm 32mm Insulation FREEZING CONDITIONS AND APPROPRIATE
MEASURES TAKEN TO PREVENT BLOCKAGE.
CORRECT INSTALLATION IN ACCORDANCE WITH
THIS SECTION WILL CONSIDERABLY MINIMISE THE
LIKELIHOOD OF BLOCKAGE AND SUBSEQUENT
BOILER LOCK-OUT.
i) Termination to an internal soil and
vent pipe A CONDENSATE DISCHARGE PUMP AND PIPE ‘TRACE
HEATING’ ARE AVAILABLE AS ACCESSORIES - see
paragraphs 7.7.12 to 7.715 for further details.
50mm
per me The condensate discharge pipe MUST NOT RISE at any
tre of
2.5° M pipe ru point along its length. There MUST be a fall of AT LEAST
inimum n
fall 2.5° (50mm per metre) along the entire run EXCEPT when
employing a suitable condensate pump in basement and
cellar or similar applications.
450mm min*
The boiler condensate trap incorporates a seal of 75mm,
*450mm is applicable to properties therefore it is unnecessary to install an air break and trap in
up to 3 storeys. the discharge pipework.
For multi-storey building installations
consult BS 6798. 1. The condensate outlet will accept 21.5mm (3/4in) plastic
Boiler overflow pipe. It is strongly recommended that this discharges
ii) External termination via internal discharge branch
internally into the household drainage system.
e.g sink waste - downstream*
Where this is not possible, discharge into an outside drain is
Sink 50mm
per me permissible providing every possible precaution is taken to
tre of
pipe ru Pipe must terminate above prevent freezing.
2.5° M n
inimum water level but below
fall
surrounding surface. Cut 2. Ensure the discharge of condensate complies with any
end at 45° national or local regulations in force. BS 6798 & Part H1 of the
Building Regulations give further detailed guidance.
*It is NOT RECOMMENDED 3. The discharge pipe should be run in a proprietary drain pipe
to connect upstream of the material e.g. PVC, PVC-U, ABS, PVC-C or PP.
sink or other waste water
receptacle ! 4. Metal pipework is NOT suitable for use in condensate
discharge systems.
Boiler
iii) Termination to a drain or gully 5. The pipe should be a minimum of 21.5mm diameter and
must be supported using suitably spaced clips of the correct
Pipe must terminate above
design to prevent sagging.
50mm water level but below
per me surrounding surface. Cut
tre of 6. It is advisable that the full length of condensate pipe is run
pipe ru end at 45°
2.5° M n internally and preferably be less than 3 metres.
inimum
fall
7. Internal runs greater than 3 metres or runs in cold areas
should use 32mm waste pipe.

8. External runs MUST be a MINIMUM of 32mm and fully

insulated with material suitable for external use.
iv) Termination to a purpose made soakaway 9. If the boiler is fitted in an unheated location the entire
Boiler
Further specific requirements for soakaway condensate discharge pipe should be treated as an external run
design are referred to in BS 6798.
and sized and insulated accordingly.
500mm min
10. In all cases discharge pipe must be installed to aid disposal of
50mm p the condensate. To reduce the risk of condensate being
er metr
e of pip Holes in the soak-away must
e run trapped, as few bends and fittings as possible should be used
2.5° Min face away from the building
imum fa and any burrs on cut pipe removed.
ll
11. When discharging condensate into a soil stack or waste pipe
the effects of existing plumbing must be considered. If soil pipes
or waste pipes are subjected to internal pressure fluctuations
when WC's are flushed or sinks emptied then back-pressure
may force water out of the boiler trap and cause appliance
lockout.
18
v) pumped into an internal discharge branch
(e.g. sink waste) downstream of the trap 7.0 Site Requirements
50mm
per me Pipe must terminate above
Sink tre of p
ipe run water level but below 7.6 Condensate Drain (cont.)
2.5° M
inimum
fall surrounding surface. Cut
end at 45° 12. A boiler discharge pump is available, ‘MULTIFIT’
part no. 720648301. This pump will dispose of both
condensate & high temperature water from the relief valve.
It has a maximum head of 5 metres. Follow the instructions
supplied with the pump.

13. Condensate Drain Pipe ‘Trace Heating’ Elements are

available in various lengths. ‘MULTIFIT’ part nos.:-
Basement or similar 1 metre 720644401
(heated)
2 metre 720664101
Boiler 3 metre 720664201
5 metre 720664401*

*Where the drain is between 3 & 5 metres a 5 metre kit can

be used and “doubled back” upon itself.

14. It is possible to fit the element externally on the

condensate drain or internally as detailed in the instructions
provided.
Condensate Pump
15. The fitting of a ‘Trace Heating’ Element is NOT a
substitute for correct installation of the condensate drain.
ALL requirements in this section must still be adhered to.
vi) pumped into an external soil & vent pipe
50mm
per me
tre of p
ipe run
2.5° M
inimum
Unheated Location fall
(e.g. Garage)

Basement or similar
(heated)
vii) to a drain or gully with extended
Boiler external run & trace heating

The ‘Trace Heating’ element

must be installed in accordance
with the instructions supplied.
Boiler External runs & those in
unheated locations still require
insulation.
Condensate Pump

50mm
per me
tre of
pipe ru
2.5° M n Pipe must terminate above
inimum water level but below
fall
surrounding surface. Cut
end at 45°

19
 Terminal Position with Minimum Distance (Fig. 17) mm
Aa Directly below an opening, air brick, opening 7.0 Site Requirements
windows, etc. 300
Ba Above an opening, air brick, opening window etc. 300
Ca Horizontally to an opening, air brick, opening window etc. 300 7.7 Flue
Db Below gutters, soil pipes or drain pipes. 25 (75)
Eb Below eaves. 25 (200) NOTE: Due to the high efficiency of the boiler a plume of
Fb Below balconies or car port roof. 25 (200) water vapour will be discharged from the flue. This should
Gb From a vertical drain pipe or soil pipe. 25 (150) be taken into account when siting the flue terminal.
Hb From an internal (i) or external (ii) corner. (i) 25 (300) (ii) 115
1. The following guidelines indicate the general requirements
I Above ground, roof or balcony level. 300
for siting balanced flue terminals. For GB recommendations are
J From a surface or boundary line facing a terminal. 600 given in BS 5440 Pt.1. For IE recommendations are given in the
K From a terminal facing a terminal (Horizontal flue). 1200 current edition of I.S. 813 “Domestic Gas Installations”.
From a terminal facing a terminal (Vertical flue). 600
L From an opening in carport (e.g. door, window) 2. If the terminal discharges onto a pathway or passageway,
into the dwelling. 1200 check that combustion products will not cause a nuisance and
M Vertically from a terminal on the same wall. 1500 that the terminal will not obstruct the passageway.
N Horizontally from a terminal on the same wall. 300
R From adjacent wall to flue (vertical only). 300 3. Take into consideration the effect the plume of vapour may
S From an adjacent opening window (vertical only). 1000
have on neighbours when siting the flue.
T Adjacent to windows or openings on pitched and flat roofs. 600 4. Adjacent surfaces close to the flue terminal may need
Table. 2 U Below windows or openings on pitched roofs. 2000 protection from the effects of condensation. Alternatively a flue
deflector kit (part no. 248167) is available.
aIn addition, the terminal should be no nearer than 150 mm to an opening in the
building fabric formed for the purpose of accommodating a built-in element such as 5. For installation of the flue into an internal corner at the
a window frame. See B.S.5440-1. 25mm dimension the flue deflector kit (part no. 248167) must
b Only ONE 25mm clearance is allowed per installation. If one of the dimensions be fitted.
D, E, F, G or H is 25mm then the remainder MUST be as shown in brackets, in 6. * Reduction to the boundary is possible down to 25mm but
accordance with B.S.5440-1. the Flue Deflector Kit (part no. 248167) must be fitted.

7. If required a suitable terminal guard is available from

Potterton for use with the flue deflector.
NOTE: The distance from a fanned draught appliance terminal 8. For fitting under low soffits and eaves the Plume
installed parallel to a boundary may not be less than 300mm in Displacement Kit or Flue Deflector Kit is recommended.
accordance with the diagram below
9. If a terminal is less than 2 metres above a balcony, above
300 min
Terminal
Assembly
* ground or above a flat roof to which people have access, then
a suitable terminal guard must be provided.

IMPORTANT:
• Under car ports we recommend the use of the plume
displacement kit.
• The terminal position must ensure the safe and
nuisance - free dispersal of combustion products.
Top View Rear Flue

Fig. 16a

Property Boundary Line

IMPORTANT: If fitting a Plume
Displacement Flue Kit, the air inlet
must be a minimum of 150mm from
any opening windows or doors (see
T
J,K Section 9.0).
U

Plume
Displacement Kit

N
R D A
M C E
I I I I
S
F B
F J,K
L A
A
G H
Air Inlet
H
I

Likely flue positions requiring

a flue terminal guard
Fig. 17 Opening Window
or Door

150mm
20 Fig. 17c MIN.
 8.0 Flue Options

8.1 Horizontal Flue Systems

Y Concentric
The maximum equivalent lengths are 4m (horizontal) or
X
(vertical). Their lengths exclude the standard elbow and
flue/terminal assembly (horizontal) and terminal assembly
(vertical).

Any additional “in line” bends in the flue system must be

taken into consideration. Their equivalent lengths are:
Horizontal
Flue System Examples Concentric Pipes: 45° bend 0.5 m
93° bend 1.0 m

NOTE: Flue length is measured from point X to Y as

Y shown.

X IMPORTANT: All flue systems must be securely

supported at least once every metre. Suitable pipe
Plume Displacement 70/110 dia Kit
supports are available as accessories.
1M Extensions, 45° & 93° bends
are also available - see Section 9.0

FLUES IN VOIDS
Consideration must be given to flue systems in voids
and the provision of adequate access for subsequent
periodic visual inspection.

NOTE: Horizontal flue pipes should always be installed with a 1.5° fall from the
terminal to allow condensate to run back to the boiler.

This bend is equivalent to

0.5 metre

B
A
Y

This bend is equivalent to

0.5 metre
X

Total equivalent length (up to 4m) =

A+B+2x45°Bends

21
 Vertical Flue System
Examples (Twin Pipe) 8.0 Flue Options

8.2 Twin & Vertical Flue Systems

Concentric
The maximum equivalent lengths are 4m (vertical). Their
Y lengths exclude the standard elbow and terminal assembly
(vertical).

X Twin Flue
The total maximum equivalent flue length is 150m.
NOTE: Each 1m of flue duct should be calculated as 2m.

Any additional “in line” bends in the flue system must be

taken into consideration. Their equivalent lengths are:

Concentric Pipes: 135° bend 0.5 m

93° bend 1.0 m
Vertical Flue
System Examples Twin Flue Pipe: 135° bend (air duct) 1.3 m
135° bend (flue duct) 2.6 m
90° bend (air duct) 4.8 m
Y 90° bend (flue duct) 9.6 m

IMPORTANT: All flue systems must be securely

supported at least once every metre. Suitable pipe
supports are available as accessories.

Total Equivalent Length =

A+B+C+1x90°Bend Roof
Terminal
All vertical and angled runs must be included, The total equivalent length
measured from the boiler adaptor (point X) to the for this example is
joint with the flue terminal (point Y). One 91.5°
bend or two 135° bends can be included without 17.2 + 34.4 = 51.6 metres.
reduction of the flue length.

If further elbows are required the flue length must

be reduced by the following amounts:-

1 metre for each 91.5° bend

Y
0.5 metre for each 135° bend AIR DUCT
C Equivalent No of Sub total
Length Value fittings/pipes
B
1m extension 1m 5 5.0m
135°bend 1.3m 2 2.6m
91.5°bend 4.8m 2 9.6m
This bend is equivalent to Equivalent Length Air Duct = 17.2m
1 metre
FLUE DUCT
A Equivalent No of Sub total
Length Value fittings/pipes
X
1m extension 2m 5 10.0m
135°bend 2.6m 2 5.2m
91.5°bend 9.6m 2 19.2m
Equivalent Length Flue Duct = 34.4m

22
 8.0 Flue Options

8.3 Flue Accessories

Key Accessory Size Code No

FLUE GROUP B
Concentric Flue System 110mm diameter
A1 B A1 Horizontal Flue Terminal 850mm 243013BAX
A
A Horizontal Flue Terminal (incl elbow) 236921
B Flue Extension 1000mm 241695
500mm 241694
250mm 241692
C Flue Bend 93° 241687
D Flue Bend (pair) 135° 241689
U Pipe Support 110mm 243014BAX
T Vertical Flue Boiler Adaptor 5106888
E S Flue Terminal Deflector 248167
T K
FLUE GROUP P
Twin Flue System 80mm diameter
E Flue Extension 1000mm 246137
500mm 246136
250mm 246135
F Flue Bend (pair) 90° 5121560
G Flue Bend (2 pair) 135° 5121561
J Vertical Flue Boiler Adaptor Kit 242757
S W Pipe Support (pair) 80mm 5111081
C D

FLUE GROUP B,P

Vertical Flue Kits
K Vertical Flue Terminal 242802
L Pitched Roof Flashing 25°/50° 243015
M Roof Cover Plate 243131
N Flat Roof Flashing 243016BAX
G F U,W

M
L

J
23
 8.0 Flue Options
For Vertical Flues
8.4 For Vertical Flue Systems
Vertical Flue
Adaptor
1. Undo the screws securing the blanking plate to the
boiler top panel. Discard the plate.

Gasket 2. Fix the vertical adaptor and gasket to the top panel with
the previously removed screws.

8.5 For Twin Flue Systems

1. Undo the screws securing the blanking plate to the

boiler top panel. Discard the plate.

2. Fix both the air and flue adaptors with their gaskets
onto the boiler top panel. Secure with screws.

For Twin Flues

Air Duct
Adaptor

Flue Duct
Adaptor
Gasket

Gasket

24
 8.0 Flue Options

8.6 For Roof Terminals

1. In the case of a pitched roof 25 - 50 degrees, position

Approx the lead tile to replace/flash over existing roof tiling. Make
1425mm an aperture in the roof suitable for the lower tube of the
roof terminal and ensure the integrity of the roof cover is
maintained. The adjustable plastic collar can either be
positioned on the lead tile or the lower tube of the roof
terminal prior to the final positioning of the vertical flue
through the tile. Check the collar is correctly located to suit
required roof pitch (either 25° to 38° or 37° to 50°). From
inside the roof adjust the flue to a vertical position and
secure to the roof structure with the clamp supplied.

2. For flat roof installations the aluminium flashing must be

incorporated into the roof covering and the appropriate
aperture made in the roof decking. The vertical flue is
Cut the same Air Duct
amount off the
lowered onto the flashing making sure the collar of the flue
Air Duct & locates securely with the flashing. (A mastic seal may be
Flue Duct Flue Duct necessary). From inside the roof, adjust the flue to a vertical
position and secure to the roof structure with the clamp
supplied.
Push Fit Adaptor
IMPORTANT: If the boiler is not fitted immediately
after the flue system, temporary precautions must be
taken to prevent rain entry into the room of installation.
Any precautionary measures must be removed prior to
commissioning the boiler.

8.7 Flue Dimensions

m
0m The standard horizontal flue kit allows for flue lengths
80
between 270mm (105/8”) and 800mm (32”) from elbow to
m
0m terminal (Fig. 18).
27

Flue Deflector The maximum permissible equivalent flue length is: 4

metres.

NOTE: Each additional 45° of flue bend will account

for an equivalent flue length of 0.5m.
e.g. 45° = 0.5m, 90° = 2 x 45° = 1m etc.
Fig. 18

8.8 Terminal Guard (Fig. 19)

Fig. 18a

1. When codes of practice dictate the use of terminal

guards, they can be obtained from most Plumbers’ and
Builders’ Merchants.

2. When ordering a terminal guard, quote the appliance

model number.

3. The flue terminal guard should be positioned centrally

over the terminal and fixed as illustrated.

8.9 Flue Deflector (Fig. 18a)

1. If required, push the flue deflector over the terminal end

Fig. 19 and rotate to the optimum angle for deflecting plume.
Secure the deflector to the terminal with screws provided.

25
 9.0 Plume Displacement
Plume Outlet (‘Peak’
MUST be Uppermost)
9.1 Plume Displacement Kit (P.D.K.)

Kit No 5121371
Content of kit
1 70/110 Concentric Flue
1 1m 70 Dia Exhaust Flue Pipe
0.94 metre
2 Support Brackets
1 93° Elbow/Plume Outlet Assembly
1 Flue Trim
2 “O” Rings
1 Elbow with Gasket

1. This kit is recommended for installations where the

condensate plume emitted from the flue may cause a nuisance
or affect the surroundings.

2. The terminal must be positioned outside the building with

the outlet connection upwards.

3. The 70Ø pipe connects to the outlet of the concentric

terminal assembly. The elbow/plume outlet must be fitted to
the end of the 70Ø pipe.

NOTE: The plume outlet must always be at least 45° to

the wall, with the ‘peak’ uppermost to prevent rain entry
(Figs. A & B), and be at least 2 metres above ground level.
It must be secured as shown in Fig. C.

The outlet must be positioned so that any condensate

plume is directed away from adjacent surfaces.
Fig. C
4. It is possible to reduce or increase (with the addition of
extensions) the length of either or both the 70/110 concentric
and 70Ø exhaust.

5. Standard concentric flue extension kits may be added

Outlet must be between the boiler elbow and the terminal assembly.
45° ‘Peak’ MUST be
at least 45° from
45° Uppermost
wall face 6. The minimum length of the concentric flue is 100mm when
measured from the edge of the boiler flue elbow. There is a
further 45mm engagement into the elbow.

IMPORTANT: The maximum equivalent length of

concentric flue is:- 4 metres
Additional elbows may be fitted in the concentric flue, but
the equivalent length must be reduced by 1 metre (93°
elbow) or 0.5 metres (45° elbow).

7. 70Ø 1 metre extensions (including support bracket), and

additional 93° & 45° elbows are available. Any additional 93°
500mm Min. & 45° elbows must be accounted for when calculating flue
lengths. 70Ø 93° elbows are equivalent to 3.5 metres of
straight length and 45° elbows to 1 metre.

Fig. A NOTE: Permitted positions of the plume outlet relative to

doors, windows etc. are the same as for conventional
concentric flues as detailed in the main Installation &
Outlet Connection Servicing Instructions and BS5440 Pt. 1. It is NOT
upwards necessary to fit a terminal guard over the air inlet or the
plume outlet.
Fig. B
26
 30 30

28 28
9.0 Plume Displacement
26 26

Ou

Ou
24 24
Ou

Ou
tp u

tp u
tpu

tpu
22 22
9.2 Determining Permissible Lengths - P.D.K.
t Se g 5

t Se g 5
tS

tS
20 20
ett

ett
ttin

ttin
18 18
in

in
gs 1 In the graph the solid line diagonal represents the

gs 1
16 16
70Ø Exhaust (metres)

70Ø Exhaust (metres)

relationship between the concentric flue assembly (and any
to

to
14 4 14

4
extensions) and the 70Ø exhaust (and any extensions or
12 12

10 10

8 8
additional bends).
6 6

4 4 Example 1 - Not Permissible

2 2
If, for instance, a concentric length of 3.25 metres was
0 0
0 1 2 3 4 0 1 2 3 4
required and the 70Ø exhaust needed to be 10 metres the
Example 1
Concentric 70/110 Flue (metres)
Example 2
Concentric 70/110 Flue (metres)
graph shows that this combination would NOT be
Flue Lengths - Not Permissible Flue Lengths - OK permissible as the intersection point would be above the
solid diagonal line.
30

28 Example 2 - Flue Lengths OK

26 Where both lengths have been determined they can be
applied to the graph to check that the installation is
Ou

24
Ou

permissible. For example, if it was known that 2 metres of

tpu
tpu

22
t Se g 5

concentric flue and 4 metres of 70Ø exhaust were required,

tS

20
ett

the values could be applied to the graph as shown in

ttin

18
in

Example 2. As the point of intersection of the dotted lines is

gs 1

16
70Ø Exhaust (metres)

below the solid diagonal line, the combination of lengths is

to

14
shown to be acceptable.
4

12

10
Example 3 - Flue Lengths OK
8
In the example shown, assume that the concentric part of
6
the flue needs to be 2 metres long. Find the position of ‘2’ on
4
the horizontal axis of the graph and then project upwards to
2
the solid diagonal line. This is represented by the vertical
0
thick dotted line. Where this dotted line intersects with the
0 1 2 3 4
Concentric 70/110 Flue (metres) solid diagonal line on the graph, project across to the vertical
Example 3 axis. As can be seen this corresponds with 14 metres.
Flue Lengths - OK Therefore, the total equivalent length of the 70Ø exhaust
can be up to 14 metres. Any elbow equivalencies must be
accounted for i.e. 93° elbows are equal to 1 metre, each 45°
elbow to 0.5 metres.
70Ø Exhaust Support
Bracket

45° Elbow
Flue Length - Worked Example
X British Gas Potterton Precision - Output Setting 5
93° Elbow
Y In Fig. D opposite an additional 93° elbow and pair of 45°
elbows have been included in the 70Ø exhaust.
1 metre Extension
Also 3 straight extension pieces have been used.

To calculate total length:-

1 metre supplied in kit
Length of 70Ø supplied in kit = 1 metre
3 x 1 metre Extensions = 3 metres
Concentric 70/110 Flue
1 x 93° Elbow = 1 metre
(MUST be installed
2 x 45° Elbow = 1 metre (0.5 metres each)
horizontally)

Concentric Flue Total 70Ø = 6 metres

Additional Accessories After consulting the table in Example 3 it can be determined

that the concentric flue could be up to approximately 3.25
A - 93° Elbow 5121373 metres long.
B - 45° Elbow (Pair) 5121374
C - 1 metre 70Ø Extension 5121372
Fig. D

27
 9.0 Plume Displacement

9.3 General Fitting Notes - P.D.K.

1. Cut a hole in the external wall which the horizontal

This section of the concentric flue assembly will pass through.
flue MUST be
horizontal 2. When completed the terminal must be at least 2 metres
Min. 2 metres above ground level (Fig. E).

3. Measure and cut to size the concentric assembly and any

extensions that are being used.

4. Insert the concentric assembly through the hole from

outside the building and mark the position of the flue trim
securing holes.
Min. 0.3 metres
5. Drill and plug the wall to accept the flue trim securing
screws, and re-insert the concentric assembly through the
wall.

6. Connect any extensions that are being used to the

concentric assembly. Engage the extension or concentric
assembly in the boiler flue elbow.

7. Fit the boiler flue elbow to the boiler top panel, ensuring
the gasket is in place (Fig. F).

Fig. E Ensure that the concentric assembly is horizontal and that

the external air inlet is to the bottom. Any extensions
should fall back to the boiler.

8. Use suitable brackets to support the concentric assembly

and any extensions, and make good inside and outside.
Secure the flue trim to the wall.

9. The 70Ø exhaust can now be fitted to the spigot at the

terminal end.

10. If it is necessary to shorten the 70Ø exhaust or any of

the extensions, the excess material must be cut from the
Fig. F plain end of the pipe.

11. Determine the position of the 70Ø exhaust and mark

on the wall a suitable position for the support bracket. Drill
and plug the wall. If extensions are being used, a support
bracket is supplied in each kit.

12. Engage the M6 threaded part of the mounting bolt in

the boss on the support bracket. Using the bracket for
leverage, screw the mounting bolt into the plugged hole
until the bracket is secure and level (Fig. G).

13. Slacken the two screws securing the retaining strap to

the bracket, and pivot the strap aside to allow fitting the
70Ø exhaust.

14. Complete the installation of the 70Ø exhaust, securing

Fig. G in the brackets. Fit the 93° elbow and plume outlet. Ensure
the plume outlet is at least 45° to the wall and that the
‘peak’ is uppermost.

15. Continue with installation and commissioning of the

boiler.

28
 9.0 Plume Displacement

Plume Outlet
Elbow 9.3 General Fitting Notes - P.D.K. (cont.)

16. For aesthetic purposes it is permissible to route the

70Ø exhaust in an enclosed box, but the air inlet and
plume outlet MUST remain in free air.

17. It is also possible to separate the plume outlet from

500
mm
Min the 93° elbow to allow the flue to be installed as shown
.
in Fig. H.

18. When the plume outlet is positioned under a balcony

or other projection (Figs. I & J) it must protrude at least
Fig. H 200mm (it is not necessary to extend it further than this).

200mm Min.

Fig. I

200mm Min.

Fig. J

29
 Template Literature Pack
10.0 Installation
Wall Plate
Check Site Requirements (section 7) before
commencing.

10.1 Initial Preparation

The gas supply, gas type and pressure must be

checked for suitability before connection (see Section
Fig. 19a 7.4).

1. Cut the banding and remove the fixing template, wall

plate and literature pack (Fig. 19a) from the carton.
Example
Edge of Boiler 96mm
2m
2. After considering the site requirements (see Section
7.0) position the template on the wall ensuring it is level
EXAMPLE: Boiler is 2 metres away both horizontally and vertically.
from corner of wall, flue duct hole is
Example 55mm up from horizontal side flue NOTE: When fitting Plume Displacement Kit refer
V = 55mm centre line. This will maintain the to the instructions supplied for details of
approx 1.5° backfall to the boiler.
installation of the flue.
Horizontal
Side Flue 3. Mark the position of the fixing holes for the wall
Centre Line plate (Fig. 20).

4. Mark the centre of the flue hole (rear exit).

Wall Thickness Flue Hole ø
For side exit: project the horizontal side flue centre line
up to 227mm 127mm core drill into the corner of the room and along the wall to
up to 750mm 150mm core drill where the flue hole will be drilled. (Fig. 20).
The diagram (Fig. 21) shows the dimensions required to
up to 1200mm 175mm core drill
Wall Plate Template ensure any horizontal flue is installed with the correct
fall to the boiler. Mark the offset (V) dimension and if
Fig. 20 required, mark the position of the gas and water pipes.
Backfall to the Boiler, ie. 2m flue offset (V) position 55mm Remove the template.
Flue Duct Hole
Offset V (mm) 13.5 27.5 55 82.5 110 (mm) 5. Cut the hole for the flue (minimum diameter
127mm, see table (Fig. 20) for wall thicknesses and flue
V 1.5° diameters).

0.5 6. Drill and plug the wall as previously marked. Secure

1.0 the wall plate (Fig. 22).

2.0
7. Ensuring the wall plate is level both horizontally and
3.0
vertically, drill and plug at least 5 securing positions at
4.0 the top and bottom through the wall plate. Utilising the
(metres)
slots available ensure the wall plate is square and secure
to the wall (Fig. 22).
Distance in metres from boiler to the wall.
For pipe lengths greater than 4m increase the off-set by 26mm
for every additional metre to maintain approx 1.5° inclination. 8. Additionally drill 2 relief holes 10mm deep in the wall
as shown on template (Fig. 22).
Fig. 21
8. Loosely route the condensate discharge pipe to the
lower left hand side of the wall plate.

Relief Holes
Wall Plate

Fig. 22
30
 10.0 Installation

10.2 Preparing The Boiler

1. Remove the outer carton and packaging.

2. Lift the outercase upwards and remove.

3. Remove the internal packaging.

Fig. 22a
Internal Polystyrene
Packaging Piece

Lower Door Panel

Outercase
Br
it
is
h
G
as

Break Off Upper &

Lower Pipe Run
Options

Fig. 23

31
 10.0 Installation

Retaining Bracket 10.3 Fitting The Boiler (Fig. 24)

1. Obtain retaining bracket and two M6 nuts from fitting

bag.

2. Offer up the boiler to the wall plate using the lifting

points shown in Fig. 24 and locate the rear bottom edge
onto the self locating support at the base of the wall plate.
(See Safe Manual Handling page 5.)

Remove the red pipe NOTE: When installing in a Loft/Small Compartment,

protection caps access for lifting the boiler from the front can be
gained for two people using the lifting points. (Fig. 24).

3. Rotate the boiler up to wall plate and engage retaining

bracket, securing with the two nuts.

4. Ensure the boiler is secured with the retaining

bracket.

5. Remove red pipe protection caps from the FLOW and

RETURN connections.

Wall Plate
Fig. 24
10.4 Making the Water Connections
Return Pipe Connection (Fig. 25)

Suggested Lifting 1. The boiler has two side water connections which are
Points shown as labelled FLOW and RETURN. The front connection is the
shaded area flow pipe and the rear threaded connection is the return.

2. It is essential that the flow and return pipes are

Flue Products Exhaust connected to the boiler correctly. The flow connection
incorporates the boiler thermostats and a flow switch.

3. The boiler connections will accept 22mm fittings.

NOTE: When the output is at setting 5 (see Section

12.1) 28mm pipe should be used to connect to the
boiler flow and return using suitable reducing fittings.
Flow Pipe
Connection 4. If the installation requires that the system pipework
originates from the bottom of the boiler, then the flow
Fig. 25 and return pipes will need cutting, as they terminate
upwards.

10.5 Making the Condensate Drain Connection

1. Connect the condensate drain using the 1”BSP nut and

seal supplied. (see section 7.6).
Fig. 25a
NOTE: To ensure the correct operation and
integrity of the condensate drainage system -
Carefully pour approximately 1 cupful (250ml) of
water into the flue products exhaust, at the top of the
heat exchanger (Fig. 25a) to ensure a seal is made in
the trap.

32
 10.0 Installation
Wall Thickness

10.6 Making the Gas Connection

1. Connect the gas supply to the G1/2 (1/2in BSPT

Internal) gas tap. This is located on the lower right side
At Least 1.5° of the boiler, access by hinging down the PCB housing
(see Fig. 32).

10.7 Fitting The Flue

Before fitting the flue, check the condensate drain

integrity (see section 10.5).

IMPORTANT: The flue should always be installed

with at least 1.5° fall from terminal to elbow, to
allow condensate to run back to the boiler.

HORIZONTAL FLUE

360° Orientation 1. The standard flue is suitable for lengths 270mm

minimum to 800mm maximum (measured from the
edge of the flue elbow outlet).

Rear Flue: maximum wall thickness - 630mm

Side Flue: maximum wall thickness - 565mm (left or right)

2. For rear exit - measure the wall thickness

(Fig. 26) and to this dimension add 181mm. This
(Z) Edge of Wall Plate to Wall dimension to be known as (X).
i.e.
(X) = wall thickness + 181
Wall Thickness
3. Take the flue and mark off (X) from the terminal end
as indicated in the diagram (Fig. 27).

Check your dimensions.

Fig. 26
The flue tubes are fixed together. Cut through both
tubes whilst resting the flue on the semi-circular packing
(Z) = Side Exit pieces. Deburr both tube ends.
Waste (X) = Rear Exit
4. For side exit - measure the distance from the edge
of the wall plate to the inner face of the wall (Fig. 26)
and to this dimension add the wall thickness + 250mm.
This dimension to be known as (Z).
i.e.
(Z) = wall plate to wall + wall thickness + 250
Flue
Fig. 27
5. Take the flue and mark off (Z) from the terminal end
as indicated (Fig. 27).

Check your dimensions.

The flue tubes are fixed together. Cut through both

tubes whilst resting the flue on the semi-circular packing
Inner Flue Support Bracket pieces. Deburr both tube ends.

IMPORTANT: Check all measurements before

cutting.

NOTE: When cutting ensure the cut does not

interfere with the inner flue support bracket
Fig. 27a (Fig. 27a).

33
 10.0 Installation

10.7 Fitting the Flue (Cont)

Inner Flue Support Bracket 6. Ensure the inner flue support bracket is positioned in
the flue (Fig. 28).

7. Engage the flue into the flue elbow using soap solution
to ease the engagement ensuring the flue is assembled as
shown (Fig. 29). Rear Flue Only:- Take the tape supplied
Fig. 28 in the kit and wrap around the joint between the flue and
the elbow (Fig. 29a).

8. Place the gasket over the flue exit on the boiler.

Flue
9. Slide the flue assembly through the hole in the wall.

10. Engage the elbow on to the flue connection on top

of the boiler. Secure with the four screws supplied in the
kit.

11. Make good between the wall and air duct outside the
Tape (Rear Flue Only) building ensuring the 1.5° drop between the terminal and
elbow.

12. The flue trim should be fitted once the installation is

Fig. 29a complete and the flue secure (Fig. 30). Apply a suitable
mastic to the inside of the trim and press against the wall
finish, making sure the brickwork is dust free and dry.
Flue Elbow
13. If necessary fit a terminal guard (see Section 8.8).
Apply Lubricant for ease of
assembly. Ensure Flue is fully
engaged into Flue Elbow VERTICAL FLUEING

1. Only a flue approved with the British Gas Potterton

Precision can be used.
Gasket

Fig. 30

Flue Trim

Fig. 29

34
 10.0 Installation

10.8 Making The Electrical Connections

NOTE: The boiler is supplied with 1 metre of 3 core

cable connected. If for any reason this is removed
re-wire as described below.

WARNING: This appliance must be earthed

1. The electrical connections are on the right hand side of

the unit.

2. Undo the two screws securing the cable clamp and place
to one side (Fig. 31).

3. Route the incoming electrical cable/s through the

grommet in the support bracket. This will prevent damage
to the cable.

4. Lay the cable through the cable clamp to gauge the length
of cable required when it is connected to the 4-way
terminal block.

5. Connect the (S/L), (N) and ( ) wires to the

4-way terminal block (Fig. 33) and refit the cable clamp
(Fig. 31).

6. Check the electrical installation for:-

earth continuity, short circuits, resistance to earth, correct
polarity and fuse failure.

Fig. 31
Cable Clamp

4-way Terminal Block

Optional Pump Feed Connection

only required for fully TRV’d system

IMPORTANT: When output is at

setting 5 (see Section 12.1) the pump
cannot be wired directly to the boiler.
Only use wiring diagrams i & ii in
S/L N P/F Section 6.6 when set to 5.

Fig. 33

35
 11.0 Electrical

11.1 Schematic Wiring Diagram

Earths not shown to aid

clarity of diagram

op

PCB g

op
w g br
b bk r w
r
pu b
pu b r
gy br b y bk
r op
gy Flow
Overheat
g/y g/y Thermostat
Output br Gas
Selector g/y Valve
b w
CH 325 Vdc Flame Spark
Flow DC Fan bk Detection Electrode
Switch bk Electrode
L N Optional
Flow Pump
Thermistor Feed
Fan g/y
Overheat Condensate
Thermostat Trap

Key To Wiring Colours

b - Blue r - Red
bk - Black g - Green
w - White g/y- Green/Yellow
br - Brown op - Opaque
gy - Grey y - Yellow
pu - Purple

36
 11.0 Electrical

11.2 Illustrated Wiring Diagram

pu
pu
b
b
Optional
Output
Pump
Selector
Feed N
L
Flow
Thermistor
y b br
r
g/y
r

b
y

br g/y
Spark
CH Electrode
Flow Switch b
gy Flame
Detection
Electrode
gy
br
br

Main
PCB
w
Layout of PCB Pins
op Condensate Trap
w

br g
r bk
b
Gas Valve
w r
g/y bk

bk Fan Overheat
Thermostat

Fan bk
Flow Overheat
Thermostat
Wiring Key

b - Blue
bk - Black
br - Brown
r - Red
w - White
g/y - Green/Yellow
g - Green
gy - Grey
op - Opaque
y - Yellow
pu - Purple
37
 12.0 Commissioning the Boiler

12.1 Commissioning the Boiler

WARNING: The PCB Control and Fan

Assembly are 325 Vdc. Isolate at supply
before access.

1. Reference should be made to BS:EN 12828 & 14336

Output Setting when commissioning the boiler.
Procedure Instruction
2. At the time of commissioning, complete all relevant
sections of the Benchmark Checklist at the rear of this
publications.

3. Flush the whole system using a suitable flushing agent

(see Section 6.2) and vent the radiators. Check for
Fig. 34a water leaks.

4. Refill the system with inhibitor following the inhibitor

Gas Service manufacturer’s instructions and BS 7593 Code of
Cock Practice for Treatment of Water in Domestic Hot
Water Central Heating Systems (see Section 6.2).

5. Complete any label supplied with the inhibitor and

attach to the inside of the boiler case. Detail of system
treatment should be added for future reference.

NOTE: The boiler output can be adjusted to suit

system demand. See the Output Setting Procedure
High
Reset
Open Instruction on the boiler front panel (Fig. 34a).
Fig. 34 This must be performed by a competent registered
person. The ELECTRICAL SUPPLY to the boiler
Low
MUST BE ISOLATED BEFORE ADJUSTMENT.
Flow Temperature Take the ‘IMPORTANT’ label from the fitting kit
ON Adjustment Screw and apply firmly over the Output Selector Switch
Cover securing screw. If the highest output is
selected 28mm pipe should be connected to the
boiler flow and return pipes.
No adjustment of the gas valve is
permissible !
Fig. 35
6. Turn the gas supply on and purge in accordance with
IGEM Publication UP/1B in GB and in IE I.S. 813
“Domestic Gas Installations”.

7. Remove the top RH securing screw and hinge down

the PCB housing to gain access to the gas service cock
(see Fig. 32). Turn the gas service cock anticlockwise to
the ON position and check for gas tightness up to the
gas valve (Fig. 34).

8. Having checked:
• That the boiler has been installed in accordance
with these instructions.
DO NOT check gas pressure here • The integrity of the flue system and the flue seals.
• The integrity of the boiler combustion circuit and
the relevant seals.
OUT

IMPORTANT: The combustion for this appliance

has been checked, adjusted and preset at the factory
for operation on the gas type specified on the
IN

appliance data plate. However, it is still necessary to

check the combustion as part of commissioning (see
Flow Chart 12.2). Do not adjust the air/gas ratio
Fig. 36
valve.
Inlet Gas Pressure Test Point

38
 12.0 Commissioning the Boiler
Perform Flue Integrity
Visual Check
Examine all flue joints for 12.2 Checking the Combustion
soundness and ensure the
system is adequately 1. This procedure is mandatory in GB from April 2014. It is
supported. strongly recommended to perform the procedure before that
date.

No Is flue system OK ? Yes Set Boiler to Maximum Rate* *To operate at Maximum Rate
Allow the combustion to Ensure all external controls are
stabilise. Do not insert probe calling for heat, that the system
to avoid ‘flooding’ the analyser. is cold and the boiler control
Rectify all faults knob is turned fully clockwise.
If necessary call
0844 871 1555 for advice.
The appliance MUST NOT be Check CO & Combustion
commissioned until all Ratio at Maximum Rate
problems are resolved. Whilst the boiler is still
operating at maximum insert
the analyser probe into the
flue gas test point, allowing the
reading to stabilise.

No Is CO < 350ppm Yes Set Boiler to operate at a low

and CO/CO2
rate. If it is not possible to adjust
ratio < 0.004 ? the boiler to run at minimum rate
Verify Integrity of Seals using the boiler controls, the
Check all burner seals, internal system must be set such that the
flue seals, door & case seals. boiler will modulate to as low an
Replace any seals that appear input as possible without the
unsound. burner extinguishing (e.g. by
closing radiator valves)
Allow the combustion to
Yes
Is CO < 350ppm stabilise. Do not insert probe to
and CO/CO2 avoid ‘flooding’ the analyser.
ratio < 0.004 ? The gas rate must be checked &
recorded whilst the boiler is
No operating in this condition.

TURN APPLIANCE OFF !

Call 0844 871 1555 for advice. No
Is CO < 350ppm
The appliance MUST NOT be
commissioned until all and CO/CO2
problems are identified and ratio < 0.004 ?
resolved. Yes
If commissioning cannot be
fully completed the appliance
must be disconnected from BOILER OPERATING
the gas supply in accordance SATISFACTORILY. NO
with the GSIUR. FURTHER ACTION
Note: Check & record the CO REQUIRED
& combustion ratio at both Ensure test points are capped,
maximum & a low rate before the boiler case front panel is
calling 0844 871 1555. correctly fitted & secured and
all other commissioning
procedures completed.
Complete the ‘Benchmark’
Checklist, recording the
CO & combustion ratio
readings as required.
39
 12.0 Commissioning the Boiler

12.3 Check the Operational (Working) Gas

Inlet Pressure

1. Ensure that all controls are calling for heat and

maximum load is applied to the system.

2. With the boiler operating in the maximum rate

condition check that the operational (working) gas
pressure at the inlet gas pressure test point is in
accordance with B.S. 6798 & B.S. 6891.

3. Ensure that this inlet pressure can be obtained with

all other gas appliances in the property working.

Measure the Gas Rate

4. With any other appliances & pilot lights turned OFF
the gas rate can be measured. It should be as shown in
Section 4.0 Technical Data.
DO NOT check gas pressure here
5. Carefully read and complete all sections of the
Benchmark Commissioning Checklist at the rear of this
OUT

publication that are relevant to the boiler and

installation. These details will be required in the event of
any warranty work. The publication must be handed to
the user for safe keeping and each subsequent regular
IN

service visit recorded.

6. For IE, it is necessary to complete a “Declaration of

Fig. 36a Conformity” to indicate compliance with I.S. 813. An
Inlet Gas Pressure Test Point example of this is given in I.S. 813 “Domestic Gas
Installations”. This is in addition to the Benchmark
Commissioning Checklist.

40
 13.0 Fitting the Outer Case

13.1 Fitting The Outer Case

Break Off Panel
1. Position the outercase over the boiler engaging the
lugs in the side flanges over the hooks on the wall plate.
Break off top or bottom panel as required to
accommodate pipework runs (Fig.37).

2. Using the two screws supplied in the kit, secure the

outercase to the combustion box (Fig. 37).

3. Hinge up the lower door panel (Fig. 38).

4. Carefully read and complete all sections of the

Benchmark Commissioning Checklist at the rear of this
publication that are relevant to the appliance and
installation. These details may be required in the event
of any warranty work. The publication must be handed
to the user for safe keeping and each subsequent
regular service visit recorded.

Bri
For IE, it is necessary to complete a “Declaration of
tish

Conformity” to indicate compliance to I.S. 813. An

Ga

Fig. 37
s

example of this is given in I.S. 813 “Domestic Gas

Installations”. This is in addition to the Benchmark
Commissioning Checklist.
Outercase Securing
Screws
5. Instruct the user in the operation of the boiler
controls. Hand over the User’s Operating, Installation
and Servicing Instructions, giving advice on the necessity
of regular servicing.

6. Demonstrate to the user the action required if a gas

leak occurs or is suspected. Show them how to turn off
the gas supply at the meter control, and advise them
not to operate electric light or power switched, and to
ventilate the property.

7. Show the user the location of the system control

isolation switch, and demonstrate its operation.

8. Advise the user that they may observe a plume of

vapour from the flue terminal, and that it is part of the
normal operation of the boiler.
Bri
tish
Ga
s

Fig. 38 9. Details of system inhibitor treatment must be

recorded in the Benchmark Commissioning Checklist.

10. Select the appropriate self-adhesive badge (‘British

Gas’ or ‘Scottish Gas’) from the fittings kit and apply to
Lower Door Panel
the recess in the outercase panel.

Position of Badge

41
 14.0 Servicing the Boiler

14.1 Annual Servicing

1. For reasons of safety and economy, it is recommended that

the boiler is serviced annually. Servicing must be performed by a
competent person in accordance with B.S. 7967-4.

2. After servicing, complete the relevant Service Interval Record

section of the Benchmark Commissioning Checklist at the rear of
this publication.

IMPORTANT: During routine servicing, and after any

maintenance or change of part of the combustion circuit, the
following must be checked:-
• The integrity of the complete flue system and the flue seals.
• The integrity of the boiler combustion circuit and relevant
seals as described in Section 14.2.
• The operational gas inlet pressure as described in Section
12.2.1 to 12.2.3 and the gas rate as described in 12.2.4.
• The combustion performance as described in ‘Check the
Combustion Performance’ (14.1.4 to 14.1.6 below).

3. Competence to carry out Checking Combustion

Performance
B.S. 6798 ‘Specification for Installation & Maintenance of Gas
Fired Boilers not exceeding 70kW’ advises that:-

• The person carrying out a combustion measurement should

have been assessed as competent in the use of a flue gas
analyser and the interpretation of the results.

• The flue gas analyser used should be one meeting the

requirements of BS7927 or BS-EN50379-3 and be calibrated
in accordance with the analyser manufacturers’ requirements.

• Competence can be demonstrated by satisfactory

completion of the CPA1 ACS assessment, which covers the
use of electronic portable combustion gas analysers in
accordance with BS 7967, Parts 1 to 4.

Check the Combustion Performance (CO/CO2 ratio)

4. Set the boiler to operate at maximum rate as described in
Section 12.2.

5. Remove the cap from the flue sampling point, insert the
analyser probe and obtain the CO/CO2 ratio. This must be
less than 0.004.

6. If the combustion reading (CO/CO2 ratio) is greater than

this, and the integrity of the complete flue system and
combustion circuit seals has been verified, and the inlet gas
pressure and gas rate are satisfactory either:
• Perform the ‘Annual Servicing - Inspection’ (Section 14.2) &
re-check.
• Replace the gas valve (Section 15.8) & re-check.

42
 14.0 Servicing the Boiler

14.2 Annual Servicing - Inspection

1. Ensure that the boiler is cool.

2. The boiler cannot be switched off at the boiler, therefore it

is important to isolate the electrical supply at the mains fuse.

3. Hazardous materials are not used in the construction of

these products, however reasonable care during service is
recommended.

4. When replacing the combustion box door after servicing it is

essential that the retaining screws are tightened fully.

5. Ensure that both the gas and electrical supplies to the

boiler are isolated.

6. Remove the outercase and lower door panel (see Fitting the
Outercase, Section 13.0).

WARNING: The PCB Control and Fan

Assembly are 325 Vdc. Isolate at supply
before access.

7. Release the four 1/4 turn screws securing the air box door
panel and remove the door (Fig. 39).

8. Disconnect the leads from the centre and right hand

Fig. 39 terminals (earth and flame sensing probe) (Fig. 40). Reconnect
Air Box Door Panel Lead Terminals in reverse order.

9. Undo the four screws securing the combustion box door

and remove the door (Fig. 41).

Earth 10. Visually check for debris/damage and clean or replace if

necessary the following:
Spark
Sleeve a) Burner.
Sensing b) Heat exchanger fins.
c) Fan compartment (Check also for condensate leaks).
Fig. 40
d) Insulation.
e) Door seals-Important: Pay particular attention to
the condition of the combustion box door seals.
f) Electrodes.
g) The condensate trap
NOTE: Remove the trap drain plug and place a vessel
underneath to catch the condensate (care should be
taken as this could be hot). Clean the trap and refit
the drain plug. Check for leaks.
h) Top of heat exchanger.

Combustion Box Fig. 41

Door Panel

43
 14.0 Servicing the Boiler

14.1 Annual Servicing - Inspection (Cont)

Flue Sampling Point
11. To clean the heat exchanger and burner proceed as
follows:

a) Disconnect the electrical leads to the fan component

protection sensor (Fig. 42).
Fig. 41a
b) Loosen the screw retaining the gas injector pipe at
the venturi (Fig. 42).

c) Undo the two wing nuts to disconnect the fan

(Fig. 42).

d) Remove the fan and disconnect the electrical supply

to it (Fig. 42).

Injector Pipe e) Remove the gas injector pipe from the gas valve
(push-fit) (Fig. 42).

f) Undo the condensate trap securing nut, lock nut and

Injector Pipe Retaining the condensate drain pipe. Remove the condensate trap
Screw and disconnect the sensor leads (Fig. 43).

g) Remove the two screws securing the burner and

remove the burner. Visually inspect the internal burner
Securing Nut
baffle for obstruction, check seal around baffle for
cracks/damage. Clean with a soft brush.
Fan

h) Loosen the two screws retaining the heat exchanger

support bracket and slide to the left to remove
Sensor
(Fig. 44).
Leads
Protection i) Remove the four screws securing the heat
Sensor Leads Electrical Supply exchanger/combustion box base and withdraw the
Condensate base.
Fig. 42 Trap
Wing Nuts
j) Lower the central insulation panel and check
Lock Nut
condition (Fig. 44). Replace the lower insulation pad if
Service Drain
necessary.
Plug
Condensate
Central Insulation Panel k) Ensure the heat exchanger fins are clear of any
Drain Pipe
obstruction.
Fig. 43
l) Check condition of all seals. Important: Pay particular
attention to the condition of the combustion box
door seals.
Burner
m) Reassemble in reverse order and check for leaks.

12. Check the CO/CO2 ratio and CO2 level at the flue
Combustion sampling point (Fig.41a) is as quoted in Section 4.0,
Box Base
‘Technical Data’.
Heat Exchanger
Support Bracket 13. If the ratio or level is greater than that quoted
telephone the Technical Enquiries for further advice.

IMPORTANT: No adjustment of the gas

valve is permissible.

Combustion Box Base 14. Complete the relevant Service Interval Record
Securing Screws section of the Benchmark Commissioning Checklist at
Burner Securing
Screws Fig. 44 the rear of this publication and then hand it back to the
user.
44
 15.0 Changing Components

15.1 Changing Components

IMPORTANT: When changing components ensure

that both the gas and electrical supplies to the boiler
are isolated before any work is started.
“The boiler cannot be switched off at the boiler,
therefore it is important to isolate the electrical
supply at the mains fuse.”
Hazardous materials are not used in the construction
of these products, however reasonable care during
service is recommended.
When replacing the combustion box door after
changing components, it is essential that the retaining
screws are tightened fully.
After Changing Components a combustion check
should be performed (see Section 15.8.11). This is
especially important on gas carrying parts, and those
that may affect combustion (e.g. fan).

1. Before changing any components please read Section

1.2 Important Information.
Fig. 45
2. Remove the outer case and lower door panel (see
Heat Exchanger “Fitting the Outercase” Section 13.0).
Manifold
WARNING: The PCB Control and Fan
Assembly are 325 Vdc. Isolate at supply
before access.

3. Isolate the water circuit and drain the system as

necessary. A drain point is located on the heat
Drain Point exchanger manifold at the right hand side of the boiler
Tube (Fig. 45) to enable the heat exchanger to be drained.

Electrical Connections 4. Place a tube on the drain point to drain water away
from electrics. Turn anticlockwise to open (Fig. 45).

NOTE: When reassembling always fit new ‘O’ rings,

ensuring their correct location on the spigot. Green
“O” rings are used for gas joints and Black “O” rings
Flow Temperature Thermistor
for water joints. Use Greasil 4000 (Approved
Silicone Grease).

5. After changing a component re-commission the

boiler where appropriate and check the inhibitor
concentration (see Section 6.2 and 12.1).

Safety
Thermostat The thermistor, safety thermostat, interface PCB and
the flow switch can be accessed after removal of the
outer case.

Fig. 46
15.2 Flow Temperature Thermistor and
Safety Thermostat (Fig. 46)

1. The procedure is the same for both the thermistor

and the safety thermostat.

2. Remove the electrical connections from the sensor.

3. Unscrew the sensor from the pipe.

4. Fit the new thermistor or safety thermostat and

reassemble in reverse order.
45
 15.0 Changing Components

15.3 Flowswitch (Fig. 47)

Support Bracket
1. Drain the boiler (see Section 15.1 paragraph 2 & 3).

2. Remove the two screws on the support bracket.

3. Remove the clip securing the flow pipe to the

flowswitch.

4. Disconnect the inline electrical connection.

5. Pull pipe away from flowswitch.

Flow Switch 6. Remove the two screws securing the flowswitch to

the boiler.

7. Remove the flowswitch.

8. Fit the new flowswitch and reassemble in reverse

order.
Flow Pipe

9. Recommission the boiler and check the inhibitor

concentration (see Section 6.2 and 12.1).
Fig. 47

Clip
15.4 PCB (Figs. 48 & 49)

WARNING: The PCB Control and Fan

Assembly are 325 Vdc. Isolate at supply
before access.

1. Remove the plastic button cover. Refit them onto the

Plastic new PCB (Fig. 48).
Button
Cover 1. Remove the top right hand securing screw and hinge
down the PCB housing and disconnect the electrical
connections noting their positions

NOTE: Check the PCB for the presence of input

jumpers - see section 10.8. Set the new PCB as the
one removed.

Hinge down 2. Lift Control PCB housing out of hinge housing of

Fig. 48 PCB Housing
metal bracket.

PCB Housing Securing 3. Fit the new PCB Housing Assembly and reassemble
Screw in reverse order.

Blue (CN11) Jumper

Red (CN12) Jumper Fig. 49

46
 15.0 Changing Components

The fan and venturi, gas valve, injector pipe,

condensate trap, fan protection sensor, spark and
sensing electrodes can be accessed and changed on
the removal of the airbox door panel.

1. Remove the airbox door panel by loosening the four

1
/4 turn screws (Fig. 50).

15.5 Spark and Sensing Electrodes

(Fig. 51)

1. Disconnect all three leads from tabs.

Spark - Opaque cable
Earth - Green/Yellow cable
Sensing - White cable

2. Remove the two screws securing each of the

electrodes to the combustion box door and remove the
electrodes.
Fig. 50
3. Fit the new electrodes (and new gasket, as required)
Air Box Door Panel and reassemble in reverse order.

15.6 Fan (Fig. 52)

WARNING: The PCB Control and Fan

Assembly are 325 Vdc. Isolate at supply
before access.

Earth 1. Loosen the screw holding the injector pipe into the
venturi.

2. Remove the electrical connections to the fan and

Sensing protection sensor on the fan.
Combustion
Spark Box Door 3. Remove the wing nuts securing the fan to the base of
the combustion box.
Fig. 51
4. Lower the fan and remove.

5. If changing the fan remove the screws securing the

venturi and fan protection sensor bracket, noting the
Injector Pipe positions of the injector opening and sensor bracket, fix
them to the new fan.
Injector
Screw Opening
6. Fit the new fan and reassemble in reverse order.
Gasket
Fan

The injector pipe, condensate trap and gas valve can

be changed after the removal of
the fan.

Protection
Sensor
Venturi
Electrical Connections

Fig. 52

Electrical Connection
Wing Nuts 47
 15.0 Changing Components

The removal of the fan is necessary to enable the

changing of the injector pipe, condensate trap and gas
valve (see section 15.6).

15.7 Injector Pipe (Fig. 53)

1. Remove the injector pipe by pulling out from the ‘O’

ring joint in the gas valve.

2. Fit the new injector pipe and reassemble in reverse

order.

Injector Pipe
15.8 Gas Valve (Fig. 53)

1. Remove the Control PCB (see Section 15.4).

Gas Valve 2. Isolate gas supply and disconnect the gas tap by
Securing Screws
removing the four screws.

3. Undo the case pressure pipe from the gas valve.

Case Pressure Pipe
4. Disconnect the electrical plug from the gas valve.
Gasket
5. Remove the fan (see section 15.6) and injector pipe.

Boiler Side 6. Remove the two gas valve securing screws from
inside the air box holding the gas valve.

7. Remove the gas valve from the airbox side.

Aluminium
Spacer
‘O ring’ 8. Remove the aluminium spacer and its gasket from
Gas Valve the gas valve.

9. Fit the aluminium spacer and gasket to the new valve.

Gas Tap 10. Fit the new gas valve and reassemble in reverse
order.
Fig. 53 Electrical Plug
NOTE: Check for gas tightness after replacing gas
valve.

11. Check the CO/CO2 ratio and CO2 level at the flue
sampling point (Fig.41a) is as quoted in Section 4.0,
‘Technical Data’.

12. If the ratio or level is greater than that quoted,

telephone the Technical Enquiries for further advice.
Securing
Nut IMPORTANT: No adjustment of the gas
Sensor
valve is permissible.
Leads

15.9 Condensate Trap (Fig. 54)

1. Disconnect the condensate trap from the base of the

heat exchanger.
Condensate
Trap 2. Disconnect the condensate drain (outside the boiler)
from the condensate trap.

3. Undo the condensate trap lock nut and remove the

trap from the boiler. Disconnect the sensor leads.
Lock Nut
Service Drain 4. Fit the new condensate trap and reassemble in
Plug reverse order.
Condensate
Drain Pipe Fig. 54 5. Prime the condensate trap (fill first chamber), check
for leaks.

48
 15.0 Changing Components

Combustion Box
The burner and heat exchanger can be changed after
Door Panel
removal of the combustion box door. To change the
heat exchanger, the fan and burner must be removed
first (see section 15.6 and 15.10).

1. Remove the combustion box door by removing the

four securing screws (Fig. 55).

IMPORTANT: On refitting the combustion box

door check the condition of the combustion box
door seals.

15.10 Burner (Fig. 56)

Support
Fig. 55 Bracket
1. Remove the two screws securing the burner to the
base of the combustion box.
Burner Return
Connection
2. Remove the burner carefully from the combustion
box base.
Fig. 57
3. Check the burner seal on the heat exchanger base,
replace if necessary. Fit the new burner and reassemble
in reverse order.

Flow
Switch 15.11 Heat Exchanger
Fig. 56
1. Drain the boiler (see section 15.1 paragraph 2 & 3).
Securing Screws
2. Remove all components in the base of the airbox.

3. Undo the screws on the support bracket. Remove

the screws securing the flow switch and return
connections and remove the connections (Fig. 57).

4. Remove the screws securing the heat exchanger

manifold and remove the manifold (Fig. 58).

5. Lift the heat exchanger assembly (Fig. 59) and rotate

the bottom upwards whilst pulling it forwards out of the
airbox.

6. Fit the new heat exchanger and reassemble in reverse

order.
Fig. 58
7. Recommission the boiler and check the inhibitor
concentration (see Section 6.2 and 12.1).
Heat Exchanger
Manifold

Heat Exchanger
Assembly

Fig. 59
49
 15.0 Changing Components

15.12 Heat Exchanger Lower Insulation Pad (Fig. 60)

1. Remove all components in the base of the airbox.

2. Remove the burner (see section 15.10).

3. Remove the four bolts securing the combustion box base.

Remove the combustion box base.

Central Insulation Panel 4. Pull the central insulation panel down from the centre of
the heat exchanger and remove the lower insulation pad.
Upper Insulation
Pad 5. Fit the new insulation pad and reassemble in reverse
order.

Lower Insulation
Pad
15.13 Heat Exchanger Upper Insulation Pad (Fig. 60)

Burner Fig. 60 1. Remove all components in the base of the airbox.

2. Remove the burner (see section 15.10).

3. Remove the heat exchanger (see section 15.11).

Combustion
Box Base
4. Remove the four bolts securing the combustion box base.
Remove the combustion box base.
Support Bracket
5. Pull the central insulation panel down from the centre of
the heat exchanger.
Combustion Box Base
Securing Screws 6. Fit the new insulation pad and reassemble in reverse
Burner Securing
Screws
order.

15.14 Output Rotary Selector Switch (Fig. 61)

Fig. 61
1. Ensure that the electrical supply to the boiler is isolated
and undo the screw securing the Output Selector Switch
Cover.

2. Note the position of the control knob. Pull the knob off
the Selector Switch. Ease the bracket to the right and
forwards, disengaging the keyhole slot from the locating
Output Selector
screw.
Switch Cover
Output Selector
3. Slacken the locknut holding the Output Selector Switch to
Switch & Bracket
the mounting bracket, remove the Switch and disconnect
the electrical plug.

4. Take the new Output Selector Switch, connect the

electrical plug and locate on the mounting bracket.

5. Secure the new Selector Switch with the locknut and refit
the knob. Engage the keyhole slot in the bracket over the
screw on the boiler.

6. Turn the knob to the position previously noted and refit

the cover. Apply the label supplied in the kit over the screw.
Output Selector
Switch

50 Label
 16.0 Short Parts List

Short Parts List

A B C
Key G.C. Description Manufacturers
No. No. Part No.

A E06 058 Flow Temperature

Thermistor (Red) 240670

B E06 059 Flow Switch 242459

C E06 060 Safety Thermostat

(Black) 242235

D PCB 5129147

E Fan 5109925
E
F Gas Valve 241900

D G E06 085 Viewing Window 242484

H Condensate Trap 5111714

I Electrodes Kit 5132097

G J Burner Assy 5107430

K E06 097 Heat Exchanger Assy 242497

51
 High
17.0 Fault Finding
Reset

NOTE: The fan is supplied with 325 Vdc.

Low

Fan Fault Finding should only be carried out after the

ON
boiler has been electrically isolated.

Lockout Boiler On Mains On General Fault Finding should only be carried out by
LED Light LED Light LED Light someone who is appropriately qualified.
(Red) (Green) (Green)

Lights
Off Off Off Go to Electrical Supply
YES
section of the fault finding
instructions. Lights
ON
On Flash On YES Go to Thermistor section
of the fault finding
instructions.
Lights ON

On Off Flash Live & Neutral Reversed

YES
Incoming Live and Neutral
Low Electrical Supply
reversed. Lights
ON Incoming Voltage less than
Flash Off Flash YES 180V. Check System
Controls & System Wiring.
Otherwise contact Electricity
Lights ON

Go to Dry-Fire Provider.
On Flash Flash
YES
section of the fault finding
instructions. LV Wiring Harness or
ON Lights
Output Selector Switch
On On On YES Ensure 8-way PCB connector
securely pushed in. If fault
Lights ON persists replace selector switch
On Off On YES or wiring harness.
Go to Ignition Lockout section
of the fault finding instructions.
ON Lights
Flash On Flash YES PCB Fault
Replace PCB.
Lights ON
Flash Off On Go to Overheat Lockout
YES
section of the fault finding
instructions.
ON Lights
On On Flash YES PCB Fault
Replace PCB.
Lights ON
Flash Flash On Go to Fan Lockout
YES
section of the fault finding
instructions.
ON
Lights
Flash On On YES PCB Fault
Replace PCB.
ON

52
 Lights 17.0 Fault Finding
Off Off Off
ELECTRICAL SUPPLY

ON

No Switched Live to
NO boiler. Check Systems
240V at A ?
Controls and System
Wiring.

YES

NO A
Check wiring from
240V at B ?
terminal block to PCB.

YES
L N Optional
Pump
Live
Check for shorts on
NO
pump, fan & gas valve.
PCB fuse OK ?
Replace if shorted &
replace fuse.

YES

Replace PCB.

B
Fuse

53
 Lights 17.0 Fault Finding
On Flash Flash
DRY-FIRE

ON

Are YES
Flow & Return reversed ? Swop Flow & Return.

NO E

Is the NO
Fill system with water and
system full of water ?
bleed out all air.

L N Optional
Pump Replace PCB.
Live
YES
YES

Turn Turn
NO NO mains off, unplug
Is the mains off & on. After 5 sec, is 7-way connector to PCB.
pump running ? there 240V Is there continuity between
F and G ?
at E?

YES NO

YES Pump or Pump Wiring Wiring from terminal

fault. block to PCB faulty.

Unplug
5-way PCB
YES
connector. Is there continuity
Replace PCB.
between H (run pump from
switched live) ?
H
G
Viewed from
Wire Entry end
NO
7-way Connector
F
Disconnect YES
Flow Switch Inline
connector. With pump running is
Wires from inline
there continuity across flow connector to PCB faulty.
switch ?

L N Optional
NO Pump
Live

Remove NO
flow switch from boiler. Is there a NO
Is there a physical blockage to blockage in the system ? Replace Flow Switch.
the paddle within the
flow switch ?

YES YES

Remove Blockage. Remove Blockage.

54
 Lights 17.0 Fault Finding
On Off On
IGNITION LOCKOUT

ON

I
Is NO
Check isolation valve and
there gas at gas valve inlet ?
gas supply. J

5-way Connector

YES

Remove
Reset Lockout. NO 5-way connector YES
Is there gas flow from gas valve. Is there 240 Replace Gas Valve.
(check at meter) ? Vdc between I & J
during ignition ?

YES NO

Remove
the larger or the
Is NO Lead from PCB to Gas
Remove Gas Valve & check two 6-way PCB connectors.
there at least NO Is there continuity from I to L
inlet filter for blockage. Valve faulty.
18mbar dynamic at gas valve Otherwise incorrect gas supply & from J to K ?
inlet ? to boiler.
YES
Replace PCB.
YES

Is
Condensate Trap
YES
Clear blockage and dry
blocked or water on sensors. K
terminals ?
L

NO
6-way Connector

Is
YES Replace spark or flame
spark or flame detection detection probe and
probe damaged ? gaskets.

NO

Is NO
spark gap between 3 and Set spark gap to 3.5mm.
4mm ?

YES

Is
wiring from PCB YES Is the NO
to spark probe & flame burner blocked or Replace PCB.
detection probe OK ? damaged ?

NO YES

Clean burner or replace as

Rectify wiring.
necessary.

55
 Lights 17.0 Fault Finding
Flash Off On
OVERHEAT LOCKOUT

ON

Disconnect
NO
black stat on flow pipe.
When flow < 60° C is there Replace Stat.
continuity across stat ?

YES

Reconnect stat. NO
Disconnect fan stat.
When fan temp < 60° C Replace Stat.
is there continuity
across stat ?

YES

Reconnect stat.
NO M
Disconnect the larger of Wiring from PCB to
the 6-way PCB connectors.
thermostats faulty.
Is there continuity
across M ?

YES 6-way Connector

Disconnect
thermistor NO
(red sensor on flow pipe). Replace thermistor.
Is resistance between
0.5kΩ & 20kΩ ?

YES

Is
combustion chamber YES Replace combustion
door seal damaged or not in chamber door seal & trim
seal.
place ?

NO

Replace PCB.

56
 Lights 17.0 Fault Finding
Flash Flash On
FAN LOCKOUT

ON NOTE: The fan is supplied with 325 Vdc.

Fan Fault Finding should only be carried out after the

boiler has been electrically isolated.

Fan PCB
Connection Connection
Unplug
3-way PCB connector NO
N O
& unplug fan. Is there Rectify wiring.
continuity from N to O &
Q
from P to Q ?
P

YES
Fan PCB
Connection Connection
Unplug
the smaller of the NO
6-way PCB connector. Is there
Rectify wiring.
continuity from R to S & from T
R
to U & from
T S
V to W ? V U
W
YES
Viewed from
Wire Entry end
Replace fan.

Lights
On Flash On
THERMISTOR

ON

Unplug
thermistor, NO
Is thermistor resistance between Replace thermistor.
0.5kΩ & 20kΩ ?

D
YES

Plug in
thermistor, leave NO
8-way connector unplugged. Wiring from PCB to
Is resistance at D between thermistor faulty. Viewed from
0.5kΩ & 20kΩ ? Wire Entry end

YES

Replace PCB.

57
 GAS BOILER SYSTEM COMMISSIONING CHECKLIST

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the
warranty. This does not affect the customer’s statutory rights.

Customer name: Telephone number:

Address:
Boiler make and model:
Boiler serial number:
Commissioned by (PRINT NAME): Gas Safe register number:
Company name: Telephone number:
Company address:
Commissioning date:

CONTROLS (tick the appropriate boxes)

Room thermostat and programmer/timer Programmable room thermostat
Time and temperature control to heating
Load/weather compensation Optimum start control
Time and temperature control to hot water Cylinder thermostat and programmer/timer Combination Boiler
Heating zone valves Fitted Not required
Hot water zone valves Fitted Not required
Thermostatic radiator valves Fitted Not required
Automatic bypass to system Fitted Not required
Boiler interlock Provided

ALL SYSTEMS
’s instructions Yes
What system cleaner was used?
What inhibitor was used? Quantity litres
Yes No

CENTRAL HEATING MODE measure and record:

Gas rate m³/hr OR ft³/hr
Burner operating pressure (if applicable) mbar OR Gas inlet pressure mbar
°C
Central heating return temperature °C

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)? Yes No
Yes No

DOMESTIC HOT WATER MODE Measure and Record:

Gas rate m³/hr OR ft³/hr
Burner operating pressure (at maximum rate) mbar OR Gas inlet pressure at maximum rate mbar
Cold water inlet temperature °C
Hot water has been checked at all outlets Yes Temperature °C
I/min

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes

ALL INSTALLATIONS
At max. rate: CO ppm AND CO/CO² Ratio
Record the following:
At min. rate: (where possible) CO ppm AND CO/CO² Ratio
The heating and hot water system complies with the appropriate Building Regulations Yes
The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions Yes
The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

Commissioning Engineer’s Signature

Customer’s Signature

*All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer.

58
© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
SERVICE RECORD

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

SERVICE 01 Date: SERVICE 02 Date:

Engineer name: Engineer name:

Company name: Company name:
Telephone No: Telephone No:
Gas safe register No: Gas safe register No:
At max. rate: CO ppm AND CO² % At max. rate: CO ppm AND CO² %
Record: Record:
At min. rate: (Where Possible) CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² %
Comments: Comments:

Signature Signature

SERVICE 03 Date: SERVICE 04 Date:

Engineer name: Engineer name:

Company name: Company name:
Telephone No: Telephone No:
Gas safe register No: Gas safe register No:
At max. rate: CO ppm AND CO² % At max. rate: CO ppm AND CO² %
Record: Record:
At min. rate: (Where Possible) CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² %
Comments: Comments:

Signature Signature

SERVICE 05 Date: SERVICE 06 Date:

Engineer name: Engineer name:

Company name: Company name:
Telephone No: Telephone No:
Gas safe register No: Gas safe register No:
At max. rate: CO ppm AND CO² % At max. rate: CO ppm AND CO² %
Record: Record:
At min. rate: (Where Possible) CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² %
Comments: Comments:

Signature Signature

SERVICE 07 Date: SERVICE 08 Date:

Engineer name: Engineer name:

Company name: Company name:
Telephone No: Telephone No:
Gas safe register No: Gas safe register No:
At max. rate: CO ppm AND CO² % At max. rate: CO ppm AND CO² %
Record: Record:
At min. rate: (Where Possible) CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² %
Comments: Comments:

Signature Signature

SERVICE 09 Date: SERVICE 10 Date:

Engineer name: Engineer name:
Company name: Company name:
Telephone No: Telephone No:
Gas safe register No: Gas safe register No:
At max. rate: CO ppm AND CO² % At max. rate: CO ppm AND CO² %
Record: Record:
At min. rate: (Where Possible) CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² %
Comments: Comments:

Signature Signature

*All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer.

59
© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
All descriptions and illustrations provided in this leaflet have been carefully
prepared but we reserve the right to make changes and improvements in
our products which may affect the accuracy of the information contained in
this leaflet. All goods are sold subject to our standard Conditions of Sale
which are available on request.

Manufactured by Potterton exclusively for British Gas

A Tr a d in g D i v i s i on o f B ax i H eat i ng U K Lt d ( 3879156)
Brooks House, Coventry Road, Warwick. CV34 4LL
e&oe

7209192 - 06 (1/14)