Potterton PRIMA 30C Bedienungsanleitung

30C, 40C, 50C & 60C

open flue gas fired boiler

FOR USE WITH NATURAL GAS (G20) ONLY

Read these instructions thoroughly before working on the boiler.

Leave the instructions adjacent to the gas meter.

GENERAL - Page 2

GAD (90/396/EEC)

POTTERTON PRIMA 30C G.C. No. 41.605.90

POTTERTON PRIMA 40C G.C. No. 41.605.91

POTTERTON PRIMA 50C G.C. No. 41.605.92

POTTERTON PRIMA 60C G.C. No. 41.605.93

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 Myson could invalidate the certification and

the normal warranty.

LIST OF CONTENTS

General Page No. 2 Installation Instructions Page No.13

Accessories Page No. 3 Commissioning Page No.19

Installation Data Page No. 3 Servicing Instructions Page No.21

Boiler Dimensions Page No. 3 Health and Safety Information Back Page

Site Requirements Page No. 5 Control Systems }Supplied in

Technical Data Page No. 7 Pipework and Wiring Guide }Literature pack

Users Instructions }

GENERAL

Once the pilot has been lit Potterton Prima C boilers are

automatic in operation. They are wall mounted natural

draught open 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 exchanger is suitable for use on open

vented gravity hot water/ pumped central systems or fully

pumped systems which may be sealed or open vented.

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 PET1

Thermostatic Radiator Valve.

Electronic Cylinder Thermostat PTT2 or PTT100

Electronic Room Thermostat PRT2 or PRT100

Motorised Zone Valve MSV222 or MSV228

Motorised Diverter Valve MSV322

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, IEE

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. BS55449 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 (mm)

GENERAL ARRANGEMENT - Page 4

Figure 2 - GENERAL ARRANGEMENT

SITE REQUIREMENTS - Page 5

These boilers are not suitable for external installation. The

appliance must not be installed in bathrooms, shower rooms,

bedrooms, bed-sitting rooms, garages or rooms where highly

inflammable materials or vapours are likely to be present.

Fitting in toilets or cloakrooms is not recommended but is

permitted, provided the combustion air is taken direct from

outside. Where installation of the boiler will be in an unusual

location special procedures may be necessary and BS6798

gives detailed guidance in 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. It is recommended that any wall

covering behind the boiler that may discolour should be

removed before mounting 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

This appliance must at all times be fitted more than 100mm

(4in) above floor level.

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.

100mm (4in) at the top.

100mm (4in) at the bottom where fitted above a working

surface etc.

Additional clearances to these may be required for

installation and are left to the discretion of the installer.

Combustion Air and Ventilation Requirements

General recommendations are given in BS5440 Part 2, and

the following notes are given as a general guide.

1. Ventilation of Compartments containing Gas Boilers

THE 60C IS NOT SUITABLE FOR INSTALLATION IN A

COMPARTMENT.

For other models there should be two permanent air vents,

one at low level and one at high level. Each opening,

whether left free or furnished with a grille, must have a

minimum effective area in accordance with Table 1.

TABLE 1

Level of Area for air whether taken

Air Vent from a Room or Outside

sq. in. sq. cm.

30C High 38 245

Low 38 245

40C High 52 335

Low 52 335

50C High 66 425

Low 66 425

There must be at least 300mm (l2in) clearance between the

grille on the front of the boiler casing and any internal

surface of the cupboard to allow for adequate air for

operation of the draught diverter.

Further details for installation of a boiler within a

compartment are given in BS6798.

2. Ventilation of rooms containing Gas Boilers.

The ventilation of the room containing the boiler shall include

air for combustion and draught diverter dilution. This applies

also when the boiler is sited in a compartment, unless the air

vents are both direct from outside.

A permanent air vent shall be provided in an outside wall of

the building at either high or low level.

SITE REQUIREMENTS - Page 6

This opening may be:

aDirectly into the room or space containing the boiler or,

bVia a duct through the wall or roof of the room, (where

such a method is considered British Gas should be

consulted) or,

cInto an adjacent room or space which has an internal

permanent air vent of the same size to the room

containing the boiler. It is undesirable to ventilate via a

kitchen, bathroom or toilet.

The air vent should be sited as far as possible from any

extract fan to avoid short circuiting. To avoid the possibility of

freezing water pipes, the vent should not be sited near pipes.

The minimum effective area of the permanent air vent must

be:

30C 22 sq cm 3.4 sq in

40C 39 sq cm 6.0 sq in

50C 56 sq cm 8.7 sq in

60C 74 sq cm 11.5 sq in

If the room (e.g. kitchen) from which air is drawn, has an

extract fan fitted, then the opening size of the permanent air

vent should take this into account to ensure that the

operation of the boiler flue is not adversely affected when the

extract fan is running with all doors and windows closed.

This should be checked in accordance with BS5440 Parts 1

and 2.

3. Grilles and Ducts

Any grille and/or duct should be so sited and of a type not to

become easily blocked or flooded and should offer low

resistance to air flow.

FLUE

A 100mm (4in) internal diameter flue must be connected to

this appliance to evacuate the products of combustion from

the boiler. The flue

connecting socket on the boiler is designed to accept flue

pipe to BS567.

If a fluepipe to BS715 is to be used an adaptor must be fitted

to the boiler connecting socket.

Reference should be made to The Building Regulations and

British Standard 5440 Part 1. The following notes have been

compiled for your guidance:-

aThe flue pipe should be at least 25mm from any

combustible material, or when passing through a wall,

floor or roof, be separated from any combustible

material by a non-combustible sleeve enclosing an air

space of at least 25mm around the flue pipe.

bIdeally a flue should rise vertically to a termination point

which is unaffected by down draught or wind eddies.

Therefore, for practical purposes, the flue should have

the shortest run possible; 90° bends should be avoided.

The terminal should be at least above roof edge level

and must be of a type acceptable to British Gas.

cWherever possible there should be at least 600mm (2ft)

of vertical flue from the boiler flue socket.

Note; A split socket should be fitted in this length.

dHorizontal runs should be avoided. If a near horizontal

length is unavoidable, it must be followed by at least

twice that length of vertical flue.

eWherever possible internal stacks, lined if necessary,

should be used.

fAll brick chimneys must be lined with a liner acceptable

to British Gas.

gWhere condensation is likely a means of draining must

be provided.

hIf an existing flue is being used, ensure that it has been

thoroughly swept before lining or connecting the boiler.

ELECTRICITY SUPPLY - Page 7

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 0.75mm2in 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 seperation of 3mm in all poles

and serving the appliance and system controls only.

TECHNICAL DATA - Page 7

Boiler Type B11Bs

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°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 36.3 kg 44.0kg

80.0 lbs 97.0 lbs

Appliance Weight - lift 31.0kg 38.5 kg

BOILER INJECTOR GAS RATE INPUT OUTPUT BURNER PRESSURE

SIZE SIZE m3/h (ft3/h) Kw(Btu/h) kW(Btu/h) Mbar in wg

Min 0.76 (26.84) 8.20 (27978) 5.86 (20,000) 7.8 3.1

30 2.6mm 0.95 (33.54) 10.18 (34734) 7.33 (25,000) 11.8 4.7

Max 1.09 (38.49) 11.72 (40000) 8.79 (30,000) 15.7 6.3

Min 1.15 (40.51) 12.29 (41930) 8.79 (30,000) 9.5 3.8

40 3.1mm 1.33 (46.98) 14.25 (48620) 10.26 (35,000) 12.7 5.1

Max 1.46 (51.49) 15.62 (53295) 11.72 (40,000) 15.3 6.1

Min 1.47 (51.90) 15.74 (53700) 11.72 (40,000) 9.3 3.8

50 3.55mm 1.65 (58.36) 17.70 (60400) 13.19 (45,000) 11.6 4.7

Max 1.81 (64.00) 19.41 (66225) 14.7 (50,000) 14.2 5.7

Min 1.86 (65.68) 19.9 (68000) 14.7 (50,000) 10.8 4.3

60 3.8mm 2.01 (70.97) 21.60 (73800) 16.12 (55,000) 13.0 5.2

Max 2.17 (76.62) 23.3 (79500) 17.6 (60,000) 15.2 6.1

TECHNICAL DATA - Page 8

Circulation Pump Selection

The resistance through the heat exchangers when operating

with a water flow rate producing an 11°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 14.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.

TABLE 2

TECHNICAL DATA - Page 9

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 4.

Gravity domestic hot water circuits should have a minimum

circulating head of 1.2m (4ft). See Fig 5. Excessive

horizontal runs should be avoided, but if this is 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 Fig 2.

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 11.

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 5 where the bathroom radiator is connected

into the gravity circuit and is fitted with two lockshield 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 boiler

terminal block as shown in Fig 13.

If a three port diverter valve is used as shown in Fig 4 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/min (1 gal/mm), see Figs 4& 6.

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/min (2 gal/min).

A suggested method of meeting these requirements by using

a bathroom radiator fitted with two Iockshield valves is

shown in FIGS. 4,6.

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 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 (45lbf/in2) shall be used. It must comply with BS6759

Part 1 and include a manual

TECHNICAL DATA - Page 10

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 1-4bar (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°C.

The vessel size can now be determined from the following

table where V = System volume in litres.

Vessel Charge 0.5 .0

Pressure (bar)

Initial System

Pressure (bar) 0.5 1.0

Expansion Vessel

Volume (litres) V x 0.833 V x 0.11

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 (5lbf/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 6

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.

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 6

METHOD 1.

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