Potterton Prima 30B Benutzerhandbuch

30B, 40B, 50B & 60B

balanced flue gas fired boiler

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

Installation and Servicing Instructions

LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER

POTTERTON PRIMA 30B G.C. No. 41 .605.94

POTTERTON PRIMA 40B G.C. No. 41 .605.95

POTTERTON PRIMA 50B G.C. No. 41 .605.96

POTTERTON PRIMA 60B G.C. No. 41 .605.97

IMPORTANT This appliance must be installed by a competent person as stated in the Gas Safety (Installation and Use)

Regulations 1994.

Prima boilers are certified for safety, it is therefore important that no external control devices (eg. flue dampers,

economisers etc.) be directly connected to these appliances unless covered by these installation instructions or otherwise

recommended in writing. Any direct connection of a control device not approved by Potterton could invalidate the

certification and the normal warranty.

LIST OF CONTENTS

General Page No.2 Installation Instructions Page No. 12

Optional Extras Page No.2 Commissioning Page No. 20

Accessories Page No.3 Servicing Instructions Page No. 22

Installation Data Page No.3 Health and Safety Information Back Page

Boiler Dimensions Page No.3 Control Systems )

Site Requirements Page No.5 Pipework and Wiring Guide, ) Supplied in Literature pack

User Instructions )

GENERAL - Page 2

Once the pilot has been lit Potterton Prima B boilers are

automatic in operation. They are wall mounted natural

draught balanced flue appliances, using a cast iron heat

exchanger and are available in four outputs ranging from

5.86-17.58kW (20,000-60,000 Btu/h).

The boilers which are designed to provide domestic hot water

and/or central heating must be used on INDIRECT hot water

systems only. The cast iron heat exchangers suitable for use

on. open vented gravity hot water/pumped central systems or

fully

pumped systems which may be sealed or open vented.

The standard balanced flue system (Part No.230043)

can be adjusted telescopically for wall thicknesses of

230mm-380mm (9-15’). Further adjustment can be made

down to a minimum wall thickness of 76mm (3) by

cutting the ducts.

For convenience, a lOOmm-175mm (4”-7’) telescopic

flue kit (Part No.230400) is available as an alternative to

the standard.

OPTIONAL EXTRAS - Page 2

The following are available as optional extras:-

FLUE EXTENSION KIT, suitable for a maximum wall

thickness of 610mm (24in)

Part No. 230230.

Part No. 230400

TERMINAL GUARD Part No.903766 to be used when the

terminal is fitted less than 2m above a balcony, above ground

or above a flat roof to which people have access.

PUMP COVER KITS, to conceal a pump at the top of a

boiler, in the following sizes:

Fixed (6in high) Part No. 225418

Adjustable (7in-1 2in) Part No. 225419

Adjustable (l3in-l8in) Part No. 225420

Adjustable (l9in-24in) Part No. 225421

ACCESSORIES - Page 3

The following range of Potterton Myson system controls are

also available and further information will be provided on

request.

Electronic Programmer EP2001, EP3001, EP4001, EP5001

and EP6000.

Programmable Electronic Thermostat PET 1.

Thermostatic Radiator Valve.

Electronic Cylinder Thermostat PTT2 or PTT1 00

Electronic Room Thermostat PRT2 or PRT1 00

Motorised Zone Valve M5V222 or MSV228

Motorised Diverter Valve M5V322

INSTALLATION DATA - Page 3

The installation of the boiler must be in accordance with the

latest relevant requirements of the Gas Safety (Installation

and Use) Regulations 1994, local building regulations, lEE

Wiring Regulations and the byelaws of the local Water

Undertaking.

Detailed recommendations are contained in the following

British Standard Codes of Practice:-

BS6798. BS5440 Part 1.

BS5440 Part 2. BS5449 Part 1.

BS5546, BS4814,

BS6891 BUILDING REGULATIONS.

MODEL WATER BYELAWS.

BRITISH GAS PUBLICATION DM2.

GAS SAFETY (INSTALLATION AND USE)

REGULATIONS 1994.

BUILDING STANDARDS (SCOTLAND)

REGULATIONS.

BOILER DIMENSIONS - Page 3

Figure 1 BOILER DIMENSIONS

BOILER DIMENSIONS - Page 4

Figure 2 GENERAL ARRANGEMENT

SITE REQUIREMENTS - Page 5

These boilers are not suitable for external installation. The

appliance may be installed in any room, although particular

attention is drawn to the requirements of the current lEE

wiring regulations and, in Scotland, the electrical provisions

of the Building Standards applicable in Scotland with

respect to the installation of the appliance in a room

containing a bath or shower.

Where a room-sealed appliance is installed in a room

containing a bath or shower, any electrical switch or

appliance control, utilising mains electricity, should be so

situated that it cannot be touched by a person using the

bath or shower.

If installed in a bathroom, the point of connection to the

external electricity supply MUST be outside the room.

Where the installation of the boiler will be in an unusual

location special procedures may be necessary and BS6798

gives detailed guidance on this aspect.

Ensure that the gas supply pipe and meter are large

enough for this appliance and any others that may be run

off the same meter. Reference should be made to BS6891.

Boiler Mounting Surface.

The boiler must be mounted on a flat wall, which may be of

combustible material and must be sufficiently robust to take

the weight of the boiler. The requirements of the local

authorities and the Building Regulations must be adhered

to.

IMPORTANT NOTICE:

TIMBER FRAMED HOUSES

If the appliance is to be fitted in a timber framed building, it

should be fitted in accordance with British Gas Publication

‘Operational Procedures for Customer Service’ Part 19. If in

any doubt, advice should be sought from the local region of

British Gas.

Clearances Around the Boiler

The following minimum clearances must be maintained

after installation for correct operation and servicing of the

boiler:-610mm (2ft) at the front of the boiler.

5mm (0.2in) each side of the boiler.

50mm (2in) at the top, except where the optional pump

cover is to be fitted, when 178mm (7in) should be allowed.

102mm (4in) at the bottom.

Additional clearances to these may be required for

installation and are left to the discretion of the installer.

Ventilation

If the boiler is to be installed in a confined space such as a

cupboard, the space will need ventilating. Openings must

be provided at the top and bottom of the cupboard each of

which should have a free area as shown in TABLE 1.

Further details for installation of a boiler within a

compartment are given in BS6798.

TABLE 1

PRIMA B Area for air Area for air

from room from outside

sq. in sq. cm sq. in sq. cm

30 16 103 8 52

40 22 140 11 70

50 27 174 14 87

60 33 208 17 104

Siting of Balanced Flue Terminal

If a terminal is less than 2m above a balcony, above

ground or above a flat roof to which people have access

then a suitable guard should be fitted (Part No. 903766).

Refer to BS5440 Part 1 for further guidance. The minimum

spacings from the terminal to obstructions and ventilation

openings are shown in Figure 3.

Note:

Where a flue is fitted less than 1000mm from a plastic or

painted gutter or 500mm from painted eaves, an aluminium

shield of 1000mm length should be fitted to the underside

of gutter or eave.

Any car port or other add-on extension should consist of a

roof or a roof and one other wall. If it consists of a roof and

two other walls the installation shall be treated as suspect

and further advice sought.

SITE REQUIREMENTS - Page 6

Figure 3 THE SITING OF BALANCED FLUE TERMINAL BOILER

POSITION MINIMUM

DISTANCE

DIRECTLY BELOW AN OPENABLE

WINDOW, AIR VENT, OR ANY OTHER

VENTILATION OPENING

BELOW GUTTER, DRAIN/SOIL PIPE

BELOW EAVES

BELOW A BALCONY OR CAR PORT

ROOF

FROM VERTICAL DRAIN PIPES AND

SOIL PIPES

FROM INTERNAL OR EXTERNAL

CORNERS

ABOVE ADJACENT GROUND OR

BALCONY LEVEL

FROM A SURFACE FACING THE

TERMINAL

FACING TERMINALS

FROM OPENING (DOOR/WINDOW) IN

CARPORT INTO DWELLING

VERTICALLY FROM A TERMINAL ON

THE SAME WALL

HORIZONTALLY FROM A TERMINAL

ON THE SAME WALL

ADJACENT TO OPENING

300

600

300

600

1200

1500

300

ELECTRICITY SUPPLY

A 240 volts — 50Hz., single phase electricity supply fused at

3A must be provided in accordance with the latest edition of

the lEE wiring regulations and any other local regulations

that may apply. The current rating of the wiring to the boiler

must exceed 3 amperes and have a cross sectional area of

at least 0.75mm2 in accordance with BS6500 1990 Table

16. The method of connection to the electricity supply

MUST

facilitate complete isolation of the appliance, preferably by

the use of a fused three-pin plug and unswitched,

shuttered socket outlet, both complying with the

requirements of BS1363. Alternatively, connection may be

made via a fused double pole isolator having a contact

separation of 3mm in all poles and serving the appliance

and system controls only.

TECHNICAL DATA - Page 6

Maximum Working Head 30.5m (l00ft)

Minimum Working Head (Fully pumped systems) 150mm (6in)

Minimum Circulating Head (Gravity systems) 1.2m (4ft)

Gas Supply Pressure 20 mbar

Maximum Flow Temperature 82 º C

Electricity Supply 240v -50Hz fused at 3A

Flow/Return Connection 28mm copper

Gas Supply Connection Rc, ½ (½ in BSP Female)

Power Consumption 20 watts

30 & 40 model 50 & 60 model

Water Content 1.8 litre 2.5 litre

0.4 gal 0.55 gal

Appliance Weight - installed 39.2 kg 46.8 kg

86.0 lbs 103.3 lbs

Appliance Weight - lift 31.0 kg 38.5 kg

68.0 lbs 85.0 lbs

TECHNICAL DATA - Page 7

BOILER

SIZE INJECTOR

SIZE GAS RATE

m3/h (ft3/h) INPUT

kW(Btu/h) OUTPUT

kW(Btu/h) BURNER

mbar PRESSURE

in wg

Min 0.72 (25.68) 7.79 (26579) 5.86 (20000) 6.8 2.7

30 2.6mm 0.89 (31.75) 9.63 (32858) 7.33 (25000) 11.2 4.5

Max 1.06 (37.88) 11.49 (39204) 8.79 (30000) 15.2 6.1

Min 1.08 (38.55) 11.69 (39900) 8.79 (30000) 8.5 3.4

40 3.1 mm 1.25 (44.80) 13.59 (46370) 10.26 (35000) 11.2 4.5

Max 1.41 (50.51) 15.32 (52280) 11.72 (40000) 15.0 6.0

Min 1.43 (51.11) 15.5 (52900) 11.72 (40000) 10.3 4.1

50 3.5 mm 1.59 (56.71) 17.20 (58700) 13.19 (45000) 12.8 5.1

Max 1.74 (62.32) 18.90 (64500) 14.65 (50000) 15.8 6.3

Min 1.81 (63.79) 19.35 (66022) 14.65 (50000) 10.0 4.0

60 3.9 mm 1.94 (69.22) 21.00 (71650) 16.12 (55000) 11.5 4.6

Max 2.09 (74.78) 22.68 (77400) 17.58 (60000) 13.5 5.4

Circulation Pump Selection

The resistance through the heat exchangers when

operating with a water flow rate producing an 110 C

temperature rise at maximum boiler output is shown in

TABLE 2. If other controls, such as three-position valves

are used in the system, the resistance through them,

quoted in their manufacturers literature must be taken into

account. The pump may be fitted on either the flow or

return and on FULLY PUMPED systems MUST be wired

directly to the boiler terminal block, see Fig 21. It must be

fitted with two isolating valves which are positioned as

close to the pump as possible. Isolation of the valves must

always leave the open vent unobstructed.

Figure 4 PRESSURE LOSS ACROSS BOILER

TECHNICAL DATA - Page 8

THE SYSTEM

The boiler must be used on INDIRECT hot water systems

only. It is suitable for use on open vented gravity hot

water/pumped central heating systems or fully pumped

systems which may be sealed or open vented.

The system should be designed so that the maximum static

head does not exceed 30.5m (l00ft) and a minimum on fully

pumped systems of 150mm (6in). See Fig 5. Gravity

domestic hot water circuits should have a minimum

circulating head of 1.2m (4ft). See Fig 6. Excessive

horizontal runs should be avoided, but if this not possible

the circulating head should be increased.

If the boiler is to be used on a system with gravity hot water

the bulb of the overheat thermostat should be repositioned

as shown on Figs 2 & 18.

To prevent reverse circulation in the gravity circuit when the

pump is running an injector disc is provided to form an

injector tee at the return connection on the boiler.

See Fig 17.

To prevent nuisance operation of the overheat thermostat,

it is important that where electrically operated zone valves

are used the boiler is wired so that it does not cycle when

the zone valves are closed. Also systems fitted with

controls that close both hot water and central heating

circuits while the boiler is still hot must be fitted with a by-

pass circuit to dissipate the residual heat within the boiler.

Further information on by-pass arrangements is provided in

later notes and illustrations.

Drain-off taps should be fitted in the pipework close to the

boiler and in low points in the system.

NOTE

Although the system can be emptied using the drain-off

taps in the pipework around the system, to empty the boiler

it is necessary to remove the drain-off plug situated in the

return header at the lower right-hand side of the casting.

See Fig 2.

COMBINED GRAVITY HOT WATER AND

PUMPED CENTRAL HEATING SYSTEMS

Where a cylinder thermostat and zone valve are fitted to

control the temperature of the domestic hot water it is

recommended that a by-pass be installed in the gravity

circuit. A suggested method of doing this is shown in Fig 6

where the bathroom radiator is connected into the gravity

circuit and is fitted with two Iockshield valves. Mechanically

operated thermostatic domestic hot water temperature

control valves which allow the boiler to operate when the

valve is closed

MUST NOT BE FITTED.

FULLY PUMPED SYSTEMS

The pump must always be wired directly to the

boilerterminal block as shown in Fig 21. If a three port

diverter valve is used as shown in Fig 5 a by-pass is not

necessary since one circuit is always open.

Where a pair of two port valves are used, a by-pass is

necessary. The total length of the by-pass circuit taken

from the boiler connections should be greater than 4

metres of 22mm pipe. It should be fitted with a lockshield

valve and adjusted to maintain a minimum flow through the

boiler of 4.5 litres/mm (1 gal/mm), see Figs 5 &7.

Systems fitted with controls which allow the boiler to

operate when both the hot water and central heating

circuits are closed (i.e. mechanically operated thermostatic

control valves) must be fitted with a by-pass circuit capable

of:-

1. Dissipating a minimum of 1 kW (3400 Btu/h).

2. Maintaining a minimum water flow through the boiler of

9 litres/mm (2 gal/mm).

A suggested method of meeting these requirements by

using a bathroom radiator fitted with two lockshield valves

is shown in Figs 5 & 7.

Additional system information can be found in the Control

Systems, Pipework and wiring guide.

SEALED SYSTEMS (FULLY PUMPED)

The installation must comply with the

requirements of BS6798 and BS5449 Part 1.

The British Gas publication ‘British Gas

TECHNICAL DATA - Page 9

Specification for Domestic Wet Central Heating Systems’

should also be consulted.

Safety Valve

A non-adjustable spring-loaded valve, pre-set to operate at

3bar (451bf/in2) shall be used. It must comply with BS6759

Part 1 and include a manual testing device. It shall be

positioned in the flow pipe either horizontally or vertically

upwards and close to the boiler. No shut-off valves are to

be placed between the boiler and safety valve. The valve

shall be installed into a discharge pipe which permits the

safe discharge of steam and hot water such that no hazard

to persons or damage to electrical components is caused.

Pressure Gauge

A pressure gauge incorporating a fill pressure indicator,

covering the range 1 -4 bar (60lbf/in2) shall be fitted to the

system. It should be connected to the system, preferably at

the same point as the expansion vessel. Its location should

be visible from the filling point.

Expansion Vessel

A diaphragm-type expansion vessel to BS4814 Part 1 shall

be fitted close to the inlet side of the pump. The connecting

pipework should not be less than 15mm (½ in nominal).

Pipework connecting the expansion vessel should not

incorporate valves of any sort. Methods of supporting the

vessel are supplied by the manufacturer. The nitrogen or

air charge pressure of the expansion vessel shall not be

less than the hydrostatic head, (height of the top of the

system above the expansion vessel). To size the expansion

vessel it is first necessary to calculate the volume of water

in the system in litres. The following volumes may be used

as a conservative guide to calculating the system volume.

Boiler Heat Exchanger 6.5 litres

Small Bore Pipework 1 litre per kW of

system output

Micro Bore Pipework 7 litres

Steel Panel Radiators 8 litres per kW

of system output

Low Water Capacity

Radiators 2 litres per kW

of system output

Hot Water Cylinder 2 litres

If the system is extended, the expansion vessel may have

to be increased unless previous provision has been made

for the extension. Where a vessel of the calculated size is

not available, the next available larger size should be used.

The boiler flow temperature is controlled at approximately

82 ºC.

The vessel size can now be determined from the following

table where V = System volume in litres

Vessel Charge

Pressure (bar) 0.5 1.0

Initial System

Pressure (bar) 0.5 1.0

Expansion Vessel

Volume (litres) Vx0.833 Vx0.11

This is a general guide; if it is required to be more accurate

refer to BS7074.

Cylinder

The hot water cylinder must be an indirect coil type or a

direct cylinder fitted with an immersion calorifier suitable for

operating at a pressure of 0.3bar (5 lbf/in2) in excess of

safety valve setting. Single feed indirect cylinders are not

suitable for sealed systems.

Method of Make-Up

Provision shall be made for replacing water loss from the

system either:-

i) from a make-up vessel or tank mounted in a position

higher than the top point of the system, and connected

through a non-return valve to the system on the return

side of all heat emitters.

ii) Where access to a make-up vessel would be difficult

by using the mains top up method or a remote

automatic pressurisation and make-up unit as

illustrated in Fig 7 METHODS 1 & 2.

Mains Connection

There shall be no connection to the mains

water supply or to the water storage tank which supplies

domestic water even through a non-return valve, without

the approval of the local Water Authority.

TECHNICAL DATA - Page 10

Filling Point

The system shall be fitted with a filling point at low level

which incorporates a stop valve to BS1010 and a double

check valve

(approved by the National Water Council) to be fitted in this

order from the system mains. refer to Fig 7 METHOD 1.

Figure 5 OPEN VENTED FULLY PUMPED SYSTEM WITH A COMBINED FEED AND VENT

Figure 6 OPEN VENTED GRAVITY DOMESTIC HOT WATER PUMPED CENTRAL HEATING

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