Potterton PRIMA 30C User Manual Download

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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.

Summary of Contents for PRIMA 30C

Page 1: ...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 ...

Page 2: ...al 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...

Page 3: ...ALLATION 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 P...

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

Page 5: ...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...

Page 6: ...he 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 a The flue pipe should be at least 25m...

Page 7: ...imum 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 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 l...

Page 8: ...ition 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 mus...

Page 9: ...EATING 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 wat...

Page 10: ... 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 vo...

Page 11: ...11 TECHNICAL DATA Page 11 Figure 4 OPEN VENTED FULLY PUMPED SYSTEM WITH A COMBINED FEED AND VENT Figure 5 OPEN VENTED GRAVITY DOMESTIC HOT WATER PUMPED CENTRAL HEATING ...

Page 12: ...12 TECHNICAL DATA Page 12 Figure 6 FULLY PUMPED SEALED SYSTEM ...

Page 13: ...ervice Cock Accessory Packs Adjustment screws Figure 7 TEMPLATE Place template in proposed boiler position taking due account of the information given previously and the position of the flue the minimum side clearances are automatically allowed for Refer to page 5 for top and bottom clearances which can be measured from the template Ensure that the template is level and mark hole positions B If th...

Page 14: ...the boiler if 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 Engage adjustment screws into the boiler legs but do not screw in fully at this stage ...

Page 15: ...rtical alignment with rear wall as necessary using the adjustment screws Remove the temporary cardboard packing pieces from either side of the casing Remove the four securing screws and withdraw the inner draught diverter assembly Check that the flueway baffles are correctly located and retained in the flueways as shown in Fig 10 Reassemble the draught diverter Make the flue connection to the boil...

Page 16: ...ped return branch of the tee as illustrated in Figs 11 11B 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 the rear connect the gas supply pipe Figure 11B WARNING UNDER NO CIRCUMSTANCES SHOULD A REDUCING SET BE FITTED Figure 12 NOTE The boiler is despatched with the overheat Th...

Page 17: ...or programmer on combined GRAVITY HOT WATER PUMPED CENTRAL HEATING systems Figure 14 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 15 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 illustr...

Page 18: ...g 16 Connect the cable to the boiler input terminals as follows Switched live on the GRAVITY DHW control circuit to terminal marked MAINS SwL Neutral to terminal marked MAINS N Earth to terminal marked MAINS Secure the cable within the clamp by tightening the two securing screws The pump should be connected to PUMPED CENTRAL HEATING control circuit at the junction box See FIG 13 Figure 17 FUNCTION...

Page 19: ...clockwise ensuring the symbol lines up with the datum mark on the gas valve body See Fig 19 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 ...

Page 20: ...ss valve should be adjusted with the boiler operating under minimum load conditions to maintain sufficient water flow through the boiler to ensure that the overheat thermostat does not operate under normal operating conditions J Remove the temporary label from the front of the casing having checked compliance with the information it contains Figure 19 GAS CONTROL VALVE Figure 20 PILOT BURNER Pilot...

Page 21: ...ential to ensure continued safe and efficient operation The frequency of cleaning will depend upon the particular installation conditions and the use to which the appliance is put but in general once per year should be adequate It is the law that all gas appliances are installed and serviced by competent persons as stated in Gas Safety Installation and Use Regulations 1994 Electrical installation ...

Page 22: ...22 SERVICING INSTRUCTIONS Page 22 Figure 21 PREPARING THE BOILER FOR SERVICING Figure 21B Figure 21C ...

Page 23: ...above and below the heat exchanger use a suitable brush and remove all deposits from between the fins When cleaning the front flueway protect the insulation inside the upper front panel by passing the front baffle into the flueway as illustrated in FIG 21 B 4 COMBUSTION CHAMBER INSULATION Check the combustion chamber insulation for damage If damaged replace as described under replacement 5 REASSEM...

Page 24: ...ND DISPOSING OF A BROKEN SIGHT GLASS a Carry out operations A B C D in section 1 PREPARING BOILER FOR SERVICE b Remove three M4 nuts from sight glass retainer and remove sight glass assembly c Replacement is the reverse of removal taking care that the clear circle in the sight glass lines up with the hole in the combustion chamber door NOTE new gaskets must be used when sight glass is fitted ELECT...

Page 25: ...e two split grommets to the new thermostat capillary carefully bend the new capillary to match the contour of the disconnected one h Ensure that the capillary is routed away from hot metallic surfaces see Fig 18a and the sensor bulb is located centrally between the two locating clips Also ensure that the location pin of the thermostat is properly located before tightening the locking nut i Make su...

Page 26: ...26 SERVICING INSTRUCTIONS Page 26 Figure 23 FAULT FINDING CHART ...

Page 27: ...974 378 496 9 2 6mm Burner Injector 30C boiler 410989 338 516 3 1mm Burner Injector 40C boiler 410990 338 517 3 55mm Burner Injector SOC boiler 410994 289 120 3 8mm Burner Injector 60C boiler 410993 338 520 10 Overheat Thermostat RANCO 404509 378 501 11 Boiler Thermostat RANCO K36 404510 378 550 12 Spark Generator VERNITRON 407693 382 887 13 Boiler Thermostat knob 225251 338 445 14 Flue Brush opti...

Page 28: ...Precautions 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 using the toilet First Aid Medical attention must be sought following eye contact or prolonged r...

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Potterton PRIMA 30C, User Manual

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