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Potterton Suprima 30L Installation & Service Instructions Manual

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Installation & Service Instructions
About the Boiler
About Safety
Supplied By www.heating spares.co Tel. 0161 620 6677
See inside cover for models covered by these instructions.
This is a Wall Mounted Fan Assisted Balanced Flue Gas Boiler.
This boiler is for use with Natural Gas (G20) only at 20mbar and for use in GB & IE.
The Gas Safety (Installation and Use) Regulations 1998.
'' In your own interest, and that of safety, it is law that all gas appliances are installed by competent
persons, in accordance with the above regulations. Failure to install appliances correctly could
lead to prosecution.''
Installation must be in accordance with the Installation & Service Instructions and the rules in
force.
Leave these instructions and the Benchmark Log Book with the user for use on future calls.
Suprima
30L - 100L
The code of practice for the installation,
Commissioning & servicing of central heating systems
TM

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  • Page 1 Installation & Service Instructions Suprima 30L - 100L About the Boiler See inside cover for models covered by these instructions. This is a Wall Mounted Fan Assisted Balanced Flue Gas Boiler. This boiler is for use with Natural Gas (G20) only at 20mbar and for use in GB & IE. About Safety The Gas Safety (Installation and Use) Regulations 1998.

  • Page 2: Table Of Contents

    Suprima 100L - G.C. No. 41 590 48 Flue Systems..........7 Flue Terminal Location........8 Potterton is a member of the Benchmark initiative and fully The System.............9 supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and 2.

  • Page 3: Technical Data

    Technical Data Nominal Boiler Ratings Boiler Input Burner setting pressure Gas Rate Output Injector Size Btu/h Btu/h mbar in wg m³/h ft³/h mm dia. models 30 000 11.0 37 500 3.70 1.05 37.1 11.2 11.7 40 000 14.7 50 000 4.50 1.40 49.3...

  • Page 4: Introduction

    Introduction Gas Safety (Installation & Use) Regulations 1998. The boilers are for use on Natural Gas (G20) only. This appliance must be installed and serviced by a competent Samples of the Suprima gas boilers have been examined person, in accordance with the above regulations. by Gastec, a United Kingdom Notified Body.

  • Page 5: Gas Supply

    IGE/UP/7/1998 (also, British Gas Service publication Part 19 - Building and Kitchen Work). If in doubt advice must be sought from Potterton. The boiler may be installed in any room, although particular attention is drawn to the requirements of the current IEE Wiring Regulations and, in Scotland, the electrical provisions of the Building Standards applicable in Scotland with respect to the installation of the boiler in a room containing a bath or shower.
  • Page 6 Fig. 1 Installation Requirements Publication No. 5102696 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 7: Air Supply

    1.6 Air Supply The air requirements must meet BS 5440 Part 2. The room in which the boiler is installed does not require a purpose provided air vent. 1.6.1 Ventilated Cupboard/Compartment: If the boiler is installed in a cupboard or compartment (with the exception of those installations covered by Section 1.6.2), permanent air vents are required in the cupboard or compartment, one at high level and one at low level, either direct to the outside air or to a room.

  • Page 8: Flue Terminal Location

    1.8 Flue Terminal Location Likely flue positions requiring Fig. 2 a flue terminal guard • Where a horizontal flue is sited less than 2m Terminal Position with Minimum Distance (mm) above a balcony, above ground, or above a flat roof to which people have access, a suitable Fanned Draught Balanced Flue terminal guard must be fitted.

  • Page 9: The System

    1.9 The System Note: Although the system can be emptied using the drain off taps installed in the pipework around the system, to Before installing a new boiler to an existing system treat the empty the boiler it is necessary to remove the drain off system with an appropriate descaling/flushing agent as per screw positioned on the heat exchanger.
  • Page 10 If the system is extended, the expansion vessel volume may have to be increased unless provision has been made for 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.
  • Page 11 Fig. 5 Fig. 6 Installation Requirements Publication No. 5102696 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 12: Installation

    Circulation Pump Selection The resistance through the heat exchanger Water Flow Rate Boiler Resistance when operating with a water flow rate producing l/min mbar an 11°C temperature rise at maximum boiler output are shown in the table. If other controls such as three position valves are used in the 17.5 0.18...

  • Page 13: Install The Flue

    7. Replace the template centrally over the hole (ensure template is level), mark two screw fixing hole positions for the mounting bracket and one for the securing point. 8. Remove the template, drill (7 mm drill) and Boiler plug the three holes. Mounting 9.
  • Page 14 7. Slide the flue back until it engages in the elbow bayonet connection, twist anti- clockwise to lock. 8. Drill through pilot hole and lock flue in position with the self tapping screw provided. 9. Make good the wall around the flue, both outside and inside.

  • Page 15: Connect The Power Supply Cable

    1. Cable clamping is provided on the front of the controls panel. Feed the cables up and over the back of the chassis, through the POTTERTON G.C. No. 41 590 42 clamp and into the terminal connection. SUPRIMA 30 L Connect the wires, brown to L, blue to N and BOILER CODE No.

  • Page 16: Install The Optional Programmer

    2.4 Install the Optional Programmer 1. Install the programmer as shown in the instructions supplied with it. 2.5 Connect the Gas Supply Ensure that the gas supply is isolated. Connect the gas supply using a suitable adaptor to the gas valve or 15 mm copper tail (100 model). Important: To prevent damage to the 'O' ring, do not solder the fitting...
  • Page 17 2.6 Connect the Water System 1. Connect system pipework to the boiler, compression fittings should be used. Note: Drain off taps should be installed close to the boiler and at the lowest points in the system. Fig. 12 Installation Publication No. 5102696 Supplied By www.heating spares.co Tel.

  • Page 18: Commissioning

    3. Commissioning POTTERTON G.C. No. 41 590 42 SUPRIMA 30 L BOILER CODE No. ALVG101 0003 11.00 Input (GROSS) Q = 37500 Btu/h 8.80 Output 30000 Btu/h 9.30 mbar Burner Pressure (HOT) in. wg 3.70 1.05 cu. m/h 50 L Model Gas Rate 37.10...
  • Page 19 The commissioning and boiler adjustment must When checking for gas soundness open only be carried out by a suitably qualified all windows and doors in the room. personnel. Potterton offer this service on a Extinguish all naked lights, cigarettes, pipes, etc. chargeable basis. Commissioning Publication No.

  • Page 20: Commission The Boiler

    3.1 Commission the Boiler First time lighting: 7. Set the temperature control knob to its maximum Open Vented Systems - Remove the pump and flush setting. The boiler will attempt to light, if the boiler the system thoroughly with cold water. Re-fit the pump. does not light within 3 attempts (due to air in the Fill and vent the system then check for leaks.

  • Page 21: Final Adjustments

    The Potterton Service Engineer, the local Gas Supplier gas valve is factory set, but if adjustment is required or a C.O.R.G.I. Registered Installer.

  • Page 22: To Service The Boiler & Component Replacement

    4. To Service the Boiler & Component Replacement • To ensure continued efficient operation of the appliance, it is recommended that it is checked and cleaned as necessary at regular intervals. • The frequency of servicing will depend upon the particular installation conditions and usage but in general once per year should be adequate.

  • Page 23: To Service The Boiler

    2. Remove the two screws securing the outer Flue Gas Slide the side panel white case to the chassis. Hinge forward, Sampling Points forward and lift-off casing pull bottom of cover forward and lift off. Put safely aside. Unscrew the side panel securing screw 4.2 To Service the Boiler 1.

  • Page 24: Electronic Control Board

    4.3.1 Electronic Control Board Gain General Access - See 4.1 1. Remove the securing screw and allow the control panel to pivot forwards. 2. Disconnect all connectors and wires, unscrew the four securing screws and remove the board. 3. On re-assembly refer to the wiring diagram when re-connecting wires and connectors.

  • Page 25: Electrode

    4.3.4 Burner 30 - 80 models Gain General Access - See 4.1 1. Disconnect the electrode lead and earth wire. 2. Undo the fixing screw, hold the burner at the right hand side and pull forwards to disconnect from the air box. 3.
  • Page 26 4.3.7 Gas Valve 30 - 80 models Gain General Access - See 4.1 1. Pull off the electrical connector at the valve. 2. Remove the gas cock by unscrewing the four long hexagonal head screws from the base of the valve. 3.

  • Page 27: Burner 100

    4.3.8 Burner 100 model Gain General Access - See 4.1 1. Disconnect the electrode lead and earth wire. 2. Undo the fixing screw, hold the burner at the right hand side. Pull forwards and to the left, disconnect from the air box and support tab.

  • Page 28: Gas Valve 100

    4.3.10 Gas Valve 100 model Gain General Access - See 4.1 1. Turn gas cock OFF, see ig.20. Pull off the electrical connector at the valve. 2. Remove the gas cock by unscrewing the four long hexagonal head screws from the top of the valve. 3.

  • Page 29: Injector S100

    4.3.11 Injectors 100 model Gain General Access - See 4.1 1. Remove the burner - See 4.3.8. 2. Use a 13mm (A/F) or ½" (A/F) socket spanner to remove the injectors. 3. Unscrew the injector, use a new sealing washer on re-assembly. 4.3.12 Fan &...

  • Page 30: Temperature Sensor

    4.3.13 Temperature Sensor Gain General Access - See 4.1 1. Disconnect the wires from the sensor. 2. Depress the clips on the outside of the sensor and pull it clear of the pipe. 3. Re-assemble in reverse order, use fresh conducting paste.

  • Page 31: Heat Exchanger

    4.3.15 Heat Exchanger Warning: For Sealed Systems relieve system pressure before draining. Gain General Access - See 4.1. 1. Drain the system at its lowest point. 2. Remove the fan and flue hood - See 4.3.12. 3. Remove the burner - See 4.3.4. (30 - 80 models) or 4.3.8.

  • Page 32: Functional Wiring Diagram

    5. Functional Wiring Diagram Boiler Lighting Sequence 1. Supply external voltage to boiler terminal connections 10.The above sequence will repeat for a further two L and N, 230 volts, 50 HZ. ignition attempts before going to lockout (indicated by 2. Supply external voltage to boiler terminal connection, the red light flashing).

  • Page 33: Wiring Diagrams

    6. Wiring Diagram Fig. 25 Wiring Diagram Publication No. 5102696 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 34: Fault Finding

    7. Fault Finding Guide Sequence of Events On start-up boiler checks that a. The reset button is not stuck ON b. The Live and Neutral are not swapped c. There is no Pump Live wiring fault d. The gas valve is not energised e.
  • Page 35 Fault Finding Publication No. 5102696 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 36: Short List Of Spares

    8. Short List Of Spare Parts Fig. 26 Short List Spare Parts Publication No. 5102696 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 37 Drg. Ref. G.C. No. Description Qty. Part No. 114 982 Electrode 8407754 114 860 Earth Lead 30 - 80 models 8238268 114 861 Earth Lead 100 model 8238269 114 863 Temperature Control 8933012 173 132 Gas Valve 30 - 80 models 402550 173 154 Gas Valve 100 model (soft light)

  • Page 38: Flue Kits

    Flue Kits ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Check availability of these kits before ordering Fig. 27 Optional Extras - Flues Publication No. 5102696 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 39 ■ ■ ■ ■ ■ Check availability of these kits before ordering Flat Roof Pitched Roof 1m Flue Extension Kit (Max. 3 Kit) ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Sales Code: ULT2EXTN Flashing Kit Flashing Kit (Not 100 models) Sales Code: Sales Code:...

  • Page 40: System And Other Kits

    System and Other Kits Installation instructions included as necessary with each kit Suprima System Kit Top Feed System Sales Code: Pipework (only for SUPSYSKIT) SUPSYSKIT Sales Code: (*Items not included in this kit) SUPSYSKITTOP SUPSYSKITDV (Complete kit shown below) 22mm Nut &...

  • Page 41: Publication No

    ■ ■ ■ ■ ■ Check availability of these kits before ordering Flue Turret Cover Boiler Stand Off Kit Sales Code: Sales Code: SUPKITI SUPKITJ Stand Off Frame Removeable Panel For Side Flue Outlet Boiler Mounting Bracket 122mm Boiler Securing Screw ■...
  • Page 42 Intentional Blank Intentional Blank Publication No. 5102696 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 43 Intentional Blank Intentional Blank Publication No. 5102696 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 44 All goods are sold subject to our standard Conditions of Sale which are available on request. Baxi Potterton Brownedge Road, Bamber Bridge Preston, Lancashire PR5 6SN www.potterton.co.uk...
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  • Page 81 • Potterton is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.
  • Page 82 Note: When the boiler is first operated, there may be a slight smell. This will disappear with use. Model POTTERTON G.C. No. 41 590 42 SUPRIMA 30 L 1. Ensure that the boiler thermostat knob is set at 'O' (fully BOILER CODE No.
  • Page 83 To avoid freezing, A Potterton Electronic Programmer or other type of clock may have been fitted in your system, together with room various methods of protection can be used:- and/or cylinder thermostats.
  • Page 84 1. Registration of Purchase General Enquiries 08706 060 780 It is important to register the purchase of your Potterton boiler to Tel. ensure you receive prompt and efficient handling in the event your boiler requires attention during the guarantee period.
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This manual is also suitable for:

Suprima 60lSuprima 40lSuprima 50lSuprima 70lSuprima 80lSuprima 100l

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