Potterton Prorile Prima 30e User guide

30e, 40e, 50e, 60e, 80e & 100e fanned
balanced flue gas fired boilers
THIS APPLIANCE IS FOR USE WITH NATURAL GAS ONLY
Installation and Servicing Instructions
LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.

POTTERTON PROFILE PRIMA
POTTERTON PROFILE PRIMA
POTTERTON PROFILE PRIMA
POTTERTON PROFILE PRIMA
POTTERTON PROFILE PRIMA
POTTERTON PROFILE PRIMA
30. G.C. No. 41.605.70
40e G.C. No. 41.605.71
500 G.C. No. 41 .605.72
60e G.C. No. 41 .605.73
80. G.C. No. 41.605.74
100. G.C. No. 41.605.75
IMPORTANT
This appliance must be installed and serviced by a competent person as stated
in the Gas Safety (Installation and Use) Regulations 1984.
Profile Prima boilers are certified by BSI for safety, it is therefore important that
no external control devices (e.g. 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 BSI certificate and the normal
warranty.
LIST OF CONTENTS
General
Optional Extras
Accessories
Installation Data
Boiler Dimensions
Page No. 2
Page No. 2
Page No. 3
Page No. 3
Page No. 3
Site Requirements
Technical Data
Installation Instructions
Commissioning
Health and Safety Information
Control Systems, Pipework and
Wiring Guide
User’s Instructions
Page No. 3
Page No. 6
Page No. 11
Page No. 18
Back Page
Supplied in
Literature Pack
GENERAL - Page 2
Profile Prima boilers are fully automatically controlled, wall
mounted, fan powered, balanced flue appliances, using a cast
iron heat exchanger and are available in six outputs ranging
from 5.86 - 29.3 kW (20,000—100,000 Btu/h).
The boilers which are designed to provide domestic hot water
and/or central heating must be used on INDIRECT FULLY
PUMPED systems only, which may be sealed or open vented.
The boilers can be supplied with either of the following types of
flue system:
Standard horizontal flue system which is suitable for a wall
thickness of 100mm (4in) to 510mm (20in).
PRIMA 100E MODEL ONLY
1 metre horizontal flue system which provides a maximum flue
length of 955mm (37in).
Vertical flue system which allows the flue to pass through a flat
roof and terminate at a maximum height of 980mm (38in)
measured from the top of boiler case.
PRIMA 30E, 40E, 50E, 60E & 80E Models only
2 metre horizontal flue system which provides a maximum
flue length of 1955mm (77in).
Vertical flue system which allows the flue to pass through a
flat roof and terminate at a maximum height of 1980mm (78in)
measured from the top of boiler case.
OPTIONAL EXTRAS - Page 2
The following are kits available as optional extras:- Internal
Internal Fitment Kit, which is suitable for a maximum
wall thickness of 510mm (20 in.) is to be used where access to
the outside wall is impracticable.
Terminal Guard, 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.
Full fitting instructions are provided with each kit.
PART Nos
Pump Cover Kit, located on top of the boiler and is designed 30e&40
e50e 60e 80e 100e
to conceal the pump, and/or any motorised valves installed Standard Flue System 213040 213040 213041 213041 213042
above the boiler. (Note: Pump cannot be fitted above the boiler 1 metre Flue System N/A N/A N/A N/A 212857
if the vertical flue kit is used). 2 metre Flue System 213043 213043 213044 213044 N/A
vertical Flue System 213046 213047 213048 213049 212830
Terminal Wall Plate, where necessary can be fitted to the Terminal Wall Plate 212306 212306 212280 212280 212280
outside wall face to improve the appearance, after making Terminal Guard 205792 205792 205792 205792 205792
good around the terminal. Internal Fitment Kit 213058 213058 213059 213059 213059
Pump Cover Kit 213056 213056 213056 213057 213057

ACCESSORIES - Page 3
The following range of Potterton system controls are also
available and further information will be provided on request.
Electronic Programmer E.P. 2001, EP. 3001, E.P.
4001, E.P. 6000.
Programmable Electronic Thermostat PET 1.
Thermostatic Radiator Valve Myson
Electronic Cylinder Thermostat PTT2
Electronic Room Thermostat PRT2
Spring Return Zone Valve PMV2
Spring Return Diverter Valve PMV3
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 1984, local building regulations, lEE Wiring
Regulations and the Bye laws of the Local Water Undertaking.
Detailed recommendations are contained in the following
British Standards and Codes of Practice.
BS6798, BS5440 Part 1
BS5440 Part 2 BS5449 Part 1
BS5546 BS4814 BS6891
BUILDING REGULATIONS 1985.
MODEL WATER BYELAWS.
BRITISH GAS PUBLICATION DM2.
GAS SAFETY (INSTALLATION AND USE) REGULATIONS
1984.
BUILDING STANDARDS (SCOTLAND)
REGULATIONS.
BOILER DIMENSIONS - Page 3
FIG. 1
Boiler 30e 40e 50e 60e 80e 100e
Dimension ‘A’ 350 350 350 350 425 425
mm) ‘B’ 110 110 110 110 150 150
‘C’ 103 103 103 103 143 143 NOTE:
‘D’ 90 90 90 107 107 107 IF PIPEWORK IS TO BE RUN DOWN THE BACK OF THE BOILER THE
NORMAL CLEARANCE OF 25mm BETWEEN THE REAR OF THE BOILER
Flow/Return
connections 22 mm Copper 22 mm Copper 22 mm Copper 22 mm Copper 28 mm Copper 28 mm Copper AND WALL CAN BE INCREASED TO 35mm IFOESIRED BY INVERTINGTHE
BOILER MOUNTING PLATE DURING INSTALLATION
(Dimensions in brackets apply when the mounting plate is inverted).
SITE REQUIREMENTS - Page 3
These boilers are not suitable for external installation and
should not be fitted directly above a cooking appliance. The
boiler may be installed in any room, although particular
attention is drawn to the requirements of the current I.E.E.
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.

SITE REQUIREMENTS - Page 4
FIG. 2 GENERAL ARRANGEMENT

SITE REQUIREMENTS - Page 5
Where the installation of the boiler will be in an unusual
location, special procedures may be necessary and BS 6798
1987 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
DM2 ‘Guide for Gas Installations in Timber Framed Housing’. If
in doubt, advice must be sought from the local Gas 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 (2 ft) at the front of the boiler
5mm (0.2 in) each Side of the boiler
50mm (2 in) at the top (measured from the top of the boiler
case), except where the optional extra pump cover is to be
fitted, when 178mm (7 in) should be allowed.
100mm (4 in) at the bottom of the boiler.
Additional clearances to these are required during installation
for lifting the boiler and 127mm (5 in) is required at the top of
the boiler for access to the pipe connections.
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
BS 6798 1987. TABLE 1
PROFILE PRIMA AIR VENT AREAS
in2cm2
30e 16 103
40e 21 135
50e 26 170
60e 32 206
80e 43 277
100e 54 349
If the openings draw air from outside the building the free
areas may be halved. Refer to BS 5440 Part 2 1976 for further
guidance.
Balanced Flue Terminal and Ducting
The fresh air inlet and flue ducts can be run from either the left,
right, rear or top of the boiler to a miniature terminal on the
outside of the building.
The minimum spacings from the terminal to obstructions and
ventilation openings are shown in FIG. 3. For information
appertaining to horizontal flue lengths reference should be
made to FIG. 4.
If a terminal is fitted less than 2m above a balcony, above
ground or above a flat roof to which people have access then a
suitable terminal guard should be fitted. (P.I.L. No. 205792).
Refer to BS5440 Part 1 1978 for further guidance.
FIG. 3 THE SITING OF BALANCED
FLUE TERMINALS
INFORMATION RELATING TO VERTICAL FLUING IS
PROVIDED IN THE PACK CONTAINING THE VERTICAL
FLUE SYSTEM.
NOTE
Where a flue terminal 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 underside of gutter
or eaves.
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.
POSITION MINIMUM DISTANCE
A. DIRECTLY BELOW AN OPENABLE
WINDOW, AIR VENT, OR ANY OTHER
VENTILATION OPENING. 300
B. BELOW GUTTER, DRAIN/SOIL PIPE 75
C. BELOW EAVES 200
D. BELOW A BALCONY OR CAR PORT ROOF 200
E. FROM VERTICAL DRAIN PIPES AND SOIL PIPES 75
F. FROM INTERNAL OR EXTERNAL CORNERS 300
G. ABOVE ADJACENT GROUND OR BALCONY LEVEL 300
H. FROM A SURFACE FACING THE TERMINAL 600
I. FACING TERMINALS 1200
J. FROM OPENING (DOOR/WINDOW) IN CARPORT
INTO DWELLING 1200
K. VERTICALLY FROM A TERMINAL ON THE SAME
WALL 1500
LHORIZONTALLY FROM A TERMINAL ON THE
SAME WALL 1500
M. ADJACENT TO OPENING 150

SITE REQUIREMENTS - Page 6
REAR OR SIDE FLUEING
FIG. 4 FLUE LENGTHS
ELECTRICITY SUPPLY
A 240 volts 50Hz, single phase electricity supply fused to 3
amperes, must be provided in accordance with the latest
edition of the I.E.E. 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 BS
6500. Table 16.
The supply to the boiler and its associated equipment
should be controlled by a 3A fused double pole switch
(having at least 3mm contact separation in both poles) so
that complete isolation from the supply can be achieved to
enable servicing work to be carried out in safety.
TECHNICAL DATA - Page 6
Maximum working head 30.5m (l00ft)
Minimum working head 150mm (6in)
Gas supply pressure 20 mbar
Maximum flow temperature 820C
Electricity supply 240v-50Hz fused at 3A
Internal Fuse Type T1A
Power Consumption 80 Watts (excluding pump)
Gas supply connection Rc. ½ (½ in BSP female)
30e, 40e, 50e & 60e Models 80e & l00e Models
Appliance lift weight (mm) 26.0kg (57.3Ibs) 33.5kg (73.871bs)
Appliance weight installed 37.1 kg (81 8lbs) 46.4kg (102.3lbs)
Water content 2.0 litre (0.44 gal) 2.4 litre (0.53 gal)
Flow/Return connections 22m copper 28mm copper

TECHNICAL DATA - Page 7
BOILER INJECTOR GAS RATE INPUT OUTPUT BURNER PRESSURE
SIZE SIZE m 3/h(ft 3/h)kW(Btu/h) kW(Btu/h) mbar in wg
Min 0.71 (25.23) 7.65 (26116) 3.9 1.6
30 2.9mm 0.87 (30.61) 9.29 (31686) 5.9 2.4
Max 1.03 (36.23) 10.99 (37500) 8.6 3.5
Min 1.06 (37.40) 11.35 (38710) 6.9 2.8
40 3.1mm 1.21 (42.86) 13.00 (44360) 9.1 3.7
Max 1.37 (48.31) 14.65 (50000) 11.6 4.7
Min 1.39 (49.11) 14.90 (50826) 8.0 3.2
50 3.5mm 1.54 (54.35), 16.49 (56250) 10.0 4.0
Max 1.71 (60.39) 18.32 (62500) 11.6 4.7
Min 1.73 (61.07) 18.53 (63211) 11.0 4.4
60 3.6mm 1.89 (66.84) 20.28 (69182) 13.0 5.2
Max 2.05 (72.46) 21.98 (75000) 15.0 6.0
Min 2.13 (75.19) 22.81 (77821) 7.2 2.9
80 4.4mm 2.43 (85.94) 26.07 (88945) 9.3 3.7
Max 2.74 (96.62) 29.31 (100000) 11.8 4.7
Min 2.78 (98.09) 29.75 (101523) 8.6 3.5
100 4.7mm 3.10 (109.38) 33.18 (113208) 10.7 4.3
Max 3.42 (120.77) 36.64 (125000) 13.1 5.3
TABLE 2
CIRCULATION PUMP SELECTION Boiler size Water Flow Rate BOILER
RESISTANCE
The resistance through the heat exchanger when operating
with a water flow rate producing an 11 0C temperature rise at Litres/sec gal. mm kN/m2in wg
maximum boiler output are shown in TABLE 2. If other 30e .19 2.5 1.5 6.0
controls, such as three-position valves are used in the system, 40e .25 3.34 3.0 12.0
the resistance through them, quoted in their manufacturer’s 50e .32 4.17 4.25 17.0
literature must be taken into account. The pump may be fitted 60e .38 5.0 6.25 25.0
on either the flow or return and MUST be wired directly to the 80e .51 6.67 7.0 28.0
boiler terminal block, see FIG. 23. It must be fitted with two l00e .64 8.4 11.0 44.0
isolating valves which are positioned as close to the pump as
possible. Closing of any valve must always leave the open
vent unobstructed.
FIG. 5 PRESSURE LOSS ACROSS BOILER

TECHNICAL DATA - Page 8
The System
The boiler must be used on INDIRECT FULLY PUMPED
systems only, 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 of 150mm (6in). See FIG 6.
On all systems the pump should be wired to the boiler terminal
block, it will then be controlled by the pump over-run
thermostat. This will ensure that the pump will continue to run
after boiler shut down if the water temperature is high, thus
preventing nuisance operation of the overheat thermostat.
It is important that where electrically operated zone valves are
used the boiler is wired so 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 from within the boiler.
If a three port diverter valve is used as shown in FIGS. 6, 7a
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 be
adjusted to maintain a minimum flow through the boiler of 4.5
litres/mm (1 gal/mm) see FIGS 6, 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).
SEALED SYSTEMS
Installation
The installation must comply with the requirements of
BS 6798 1987 and BS 5449 Part 1. The B.G. publication
“British Gas Specification for Domestic Wet Central
Heating Systems” should also be consulted.
Safety Valve
A non-adjustable spring-loaded safety valve, preset to operate
at 3 bar (451bf/in2) shall be used. It must comply with BS 6759
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 the safety valve. The valve
should 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 0-4 bar (60Ibf/in5) 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 (1,’2in nominal).
Pipework connecting the expansion vessel should not
incoporate 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 point 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.
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. 6, 7.
Additional system information can be found in the Control
Systems, Pipework and Wiring Guide.
Drain off taps should be fitted in the pipework close to the
boiler and in the low points of the system.
NOTE
Although the system can be emptied using the drain off taps
installed in the pipework around the system, to empty the
boiler it is necessary to remove the drain off cap positioned
within the boiler case. See FIG. 2.
Boiler Heat Exchanger:
Small Bore Pipework:
Micro Bore Pipework:
Steel Panel Radiators:
Low Water Capacity Radiators:
Hot water Cylinder:
6.5 litres
1 litre per kW of
system output
7 litres
8 litres per kW of
system output
2 litres per kW of
system output
2 litres

TECHNICAL DATA - Page 9
If the system is extended, the expansion vessel volume 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
820C.
The vessel size can now be determined from the following
table where V=System volume in litres.
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 hot water cylinder or the return side of all heat
emitters.
or
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 and 2.
Vessel Charge Pressure(bar) 0.5 1.0
Initial System Pressure (bar) 1.0 1.0 Mains Connection
Expansion Vessel Volume (litres) V x 0.11 V x 0.087 There shall be no connection to the mains water supply or to
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 gauge pressure of 0.3 bar (Slbf/in2) in excess of
safety valve setting. Single feed indirect cylinders are not
suitable for sealed systems.
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 BS1 010 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.
FIG. 6 OPEN VENTED FULLY PUMPED SYSTEM FITTED
WITH A COMBINED FEED AND VENT

TECHNICAL DATA - Page 10
FIG 7 FULLY PUMPED SYSTEM