Potterton Prima 30B Installation And Servicing Instructions Download

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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

Summary of Contents for Prima 30B

Page 1: ...1 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 ...

Page 2: ...n 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 cen...

Page 3: ...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 BS544...

Page 4: ...4 BOILER DIMENSIONS Page 4 Figure 2 GENERAL ARRANGEMENT ...

Page 5: ...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 ...

Page 6: ...f 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 connecti...

Page 7: ... 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 quo...

Page 8: ...n 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 connec...

Page 9: ...tem 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 ...

Page 10: ...orporates 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 ...

Page 11: ...11 TECHNICAL DATA Page 11 Figure 7 FULLY PUMPED SEALED SYSTEM ...

Page 12: ...System Pipework and Wiring Guide Auxilliary Pack containing Gas Service Cock Accessory Packs Adjustment screws CARTON 2 Inner Flue Product Tube Outer Flue Product Tube Air Box Air Tube Terminal Boiler Mounting Plate Figure 9 SECURING BOILER MOUNTING PLATE Using wall plugs screws and washers accessory pack A attach boiler mounting plate to wall Ensure that it is level and the correct way round i e ...

Page 13: ...not pull controls cover forward 25mm lower to release from the four side fixings and pull forward clear of the thermostat knob Remove door by undoing the two lower fixing screws and lift door off the two upper hinge brackets Remove two screws securing the fluehood and remove fluehood by sliding forward to disengage it from rear location ...

Page 14: ...g table For wall thicknesses between 100mm 175mm 4in 7in the alternative telescopic Flue Kit can be used for additional convenience Using the packaging material to protect the boiler from damage lay the boiler on its side and secure the Air Box to the boiler using the nine M4 screws from accessory pack B Engage adjustment screws into the boiler legs but do not screw in fully at this stage WALL THI...

Page 15: ...imum of 5mm clearance from any side wall or cupboard Secure boiler to the mounting bracket using 5mm screw from accessory pack C Undo the screws securing the transportation feet Discard feet and screws Correct vertical alignment with rear wall as necessary using the adjustment screws Remove the temporary cardboard packing pieces from either side of the casing ...

Page 16: ...ed but do not fully tighten NOTE these screw positions are not symmetrical to ensure correct assembly with the Terminal Slide Terminal on to the Outer Flue Product Tube engaging fully the slots in the Terminal under the heads of the four screws in the Outer Flue Product Tube Secure terminal by tightening the four screws Slide the Terminal Assembly into the Air Duct engaging the Outer Flue Product ...

Page 17: ...ed return branch of the tee as illustrated in Figs 17 17B Remove gas service cock from the auxilliary pack and attach it to the union nut on the inlet to the gas assembly With the inlet connection of the gas service cock facing to the rear connect the gas supply pipe Figure 17B WARNING UNDER NO CIRCUMSTANCES SHOULD A REDUCING SET BE FITTED Figure 18 NOTE The boiler is despatched with the overheat ...

Page 18: ... or programmer on combined GRAVITY HOT WATER PUMPED CENTRAL HEATING systems Figure 20 ACCESS TO THE BOILER ELECTRICAL TERMINAL BLOCK Remove control box securing screw and lower the control box to gain access to the boiler terminal block Figure 21 WIRING THE BOILER FOR A FULLY PUMPED SYSTEM Route a four core cable through the plastic bush at the rear of the control box and the cable clamp as illust...

Page 19: ...g the two securing screws The pump should be connected to PUMPED CENTRAL HEATING control circuit at the junction box See Fig 19 Figure 23 FUNCTIONAL FLOW DIAGRAM Figure 24 BOILER WIRING DIAGRAM Figure 24A FITTING SIDE INFILL PANELS If required the gap between the casing sides and rear wall can be closed off using the infill panels supplied Ensure the casing surface is FULLY CLEAN AND DRY Remove th...

Page 20: ...m mark on the gas valve body See Fig 25 This ensures that the valve is in the OFF condition G Partly depress and turn the control knob anti clockwise until the symbol lines up with the datum mark on the gas valve body Press and hold in the control knob and press the spark generator button until a click is heard Release the spark generator button and repeat operation until the pilot ignites See Fig...

Page 21: ...achieved check that the inlet pressure is 20 mbar See Fig 25 for inlet test nipple position If this is correct contact Potterton Myson Boiler Thermostat At its minimum and maximum settings the thermostat should control the water flow temperature at approximately 550 C 820 C 1 300 F 1 800 F The thermostat has been calibrated by the makers and no attempt should be made to re calibrate it on site Tur...

Page 22: ...o the inside of the plastic controls cover The boiler CODE NUMBER which should be quoted when ordering spares or requesting information is on the front of the control box The following notes apply to the boiler and its controls but it should be remembered that attention must also be paid to the heating circuit itself including radiator valves thermostats the time control and the expansion and feed...

Page 23: ... flame is distorted or the wrong size i e too small Disconnect the electrode lead from the electrode uncouple the thermocouple and pilot gas tube nuts at the base of the pilot assembly and lift out the pilot Note the pilot injector sits loosely on top of the pilot tube or may be retained in pilot head itself Remove and inspect the pilot injector for dirt deposits and clean if necessary Likewise in...

Page 24: ...mocouple lead from the interrupter connection on the gas control valve and at the pilot NOTE The interrupter connector is held in place by the thermocouple lead Withdraw thermocouple from grommet noting the route the lead takes so that the replacement can be routed in a similar manner to eliminate sharp bends d Replacement is the reverse of removal Ensure on reassembly that the sealing plate and s...

Page 25: ...f Remove the nut securing the thermostat to the control box g Remove the split pin retaining the thermostat bulb and withdraw bulb from its pocket h Remove split grommet in the base of the boiler and the split grommet from the side of the control box and feed thermostat capillary and bulb through holes i Replacement is the reverse of removal The bulb of the new thermostat should be coated with hea...

Page 26: ...26 SERVICING INSTRUCTIONS Page 26 Figure 28 FAULT FINDING CHART ...

Page 27: ...3 8 Gas Control valve S I T NOVA 402974 378 496 9 2 6mm Burner Injector 30B boiler 410989 338 516 3 1 mm Burner Injector 40B boiler 410990 338 517 3 5mm Burner Injector 5GB boiler 410991 338 518 3 9mm Burner Injector 6GB boiler 410992 338 519 10 Overheat Thermostat RANCO 404509 378501 11 Boiler Thermostat RANCO K36 404510 378 550 12 Spark Generator VERNITRON 407693 382 887 13 Boiler Thermostat kno...

Page 28: ...of the skin Fibre entry into the eye will cause foreign body irritation Irritation to respiratory tract People with a history of skin complaints may be particularly susceptible to irritation High dust levels are only likely to arise following harsh abrasion In general normal handling and use will not present discomfort follow good hygiene practices wash hands before consuming food drinking or usin...

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Potterton Prima 30B, Installation And Servicing Instructions

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