Preparing The Boiler; Main Burner Assembly - Removal And Cleaning; Main Burner Assembly - Replacement; Final Adjustments - Potterton Flamingo RS40 Installation And Service Manual

replacement which is available from Interpart spares stockists, or where difficulty in supply is experienced,
directly from Potterton International Limited.

1. PREPARING THE BOILER

a. Pull off the boiler thermostat knob, then unscrew the screw securing the controls cover and slide the
cover from the boiler.
b. Unscrew the two captive securing screws at the bottom of the casing and the single captive screw at the
top, then withdraw the casing from the boiler.
c. Unscrew the four screws securing the combustion chamber front coven and remove the cover.

2. MAIN BURNER ASSEMBLY - REMOVAL AND CLEANING

a. Unscrew the wingnut securing the main burner to the right-hand side mounting bracket inside 'the
combustion chamber. On the Flamingo R5505 boiler, undo the two screws securing the pilot plate to the
burner. Lift out the burner taking care not to damage the pilot assembly or insulation. Remove all deposits
from the burner.
On the Flamingo RS50S boiler it will be necessary to lift the right hand side of the burner into the top right-
hand corner of the combustion chamber so that the burner can clean the injector. By moving the burner
forward and to the left, it can now easily be removed.
b. Do not attempt to refit the main burner assembly into the combustion chamber at this stage, as the
flueways in the heat exchanger have to be cleaned first.
c. Drape a suitable cloth over the pilot burner assembly so that when the heat exchanger is cleaned, the
dirt removed does not foul the pilot, ignition electrode or thermocouple.
3. HEAT EXCHANGER
a. Unscrew the two nuts and remove the hooks and strap. Lift off the fluehood.
b. Working from above and below the heat exchanger, use a suitable brush and remove all deposits from
between the fins of the casting.
c. Refit the fluehood, ensuring that a good seal is made with both the boiler backplate and the top of the
heat exchanger. Tighten the two nuts. Ensure hooks are engaged correctly.
d. Remove the cloth covering the pilot burner assembly and clean any deposits from the pilot, ignition
electrode or thermocouple.

4. MAIN BURNER ASSEMBLY - REPLACEMENT

Replace the main burner in position and secure it with the wingnut. On the Flamingo RS50S boiler it will be
necessary to slide the burner into the combustion chamber from the left hand side, lift the leading edge of
the burner into the top right hand corner of the heat exchanger and feed the air box over the injector.
Secure the burner with the wingnut. Refit pilot plate to bracket on burner, two screws.
5. OTHER BOILER COMPONENTS
No further replacement has to be carried out on any other unit. Repair is by replacement and instructions
on this are given later.

6. FINAL ADJUSTMENTS

a. Refit the combustion chamber front cover and secure it with the four screws. Ensure an air tight seal is
obtained all around the edge of the cover.
b. Fit the thermostat knob onto its spindle.
c. Connect the pressure gauge to the pressure test nipple on the Honeywell Compact Control Valve (figure
1).
d. Switch on the main electricity supply to the boiler and check that the boiler thermostat is in the off
position.
e. Turn on the main gas supply.
f. Ensure that the system is full of water and that the pump and radiator isolating valves are open.
g. Ensure that the time control, if fitted, is in an 'on' condition, and that the room and/or cylinder
thermostats, where fitted, are set to high temperatures.
h. Turn the control button on the gas control valve clockwise as far as possible (approximately 1/12th of a
turn) then release it. This ensures that the valve is in the 'off' condition.
j. Press and hold in the start or control button on the gas control valve, then press in the Piezo igniter
button but continue to hold in the start or control button and check through the site glass, that the pilot has
lit; hold in the start or control button for a further 20 seconds, then release it and the pilot should remain
alight.
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Service Section – Page 17