Potterton Suprima 30 HE Installation & Service Instructions Manual
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Potterton Suprima 30 HE Installation & Service Instructions Manual

Condensing central heating boiler
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Installation & Service Instructions
Suprima
30 - 80 HE
Condensing
Central Heating Boiler
Only a flue approved for the Suprima HE can be used.

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Summary of Contents for Potterton Suprima 30 HE

  • Page 1 Installation & Service Instructions Suprima 30 - 80 HE Condensing Central Heating Boiler Only a flue approved for the Suprima HE can be used.

  • Page 2: Table Of Contents

    7. Control Sequence.........24 Failure to commission the boiler correctly may 8. Fault Finding Guides........25 result in the installer being charged for any visits 9. Servicing & Parts Replacement....32 made by Baxi Potterton. Servicing Procedure........32 General Access..........34 PCB Enclosure..........34 Gas Valve............34 Air Pressure Switch........35...

  • Page 3: Introduction

    1. Introduction Identification Potterton Suprima HE To gain access to the identification labels, pull the door Suprima 30 HE G.C. No. 41 075 35 Suprima 40 HE G.C. No. 41 075 36 down. Suprima 50 HE G.C. No. 41 075 37 Suprima 60 HE G.C.

  • Page 4: Technical Data

    2. Technical Data 30 HE 40 HE 50 HE 60 HE 70 HE 80 HE Heat Input - Gross 10.22 13.62 17.04 20.43 23.84 27.25 Btu/h 34,877 46,465 58,129 69,717 81,343 92,968 Heat Output 8.82 11.78 14.76 17.72 20.68 23.63 (Non Condensing) Btu/h 30,093...
  • Page 5 Return Connection Flow Connection Flow Sensor Overheat Sensor Casting Sensor Air Pressure Switch 'O' Ring and Clip Joints Fan and Flue Hood Secondary Heat Exchanger Primary Heat Exchanger Burner & Electrodes Data Label Wiring Centre PCB Enclosure Condensate Trap 75 mm Gas Connection 410 mm overall Gas Valve...

  • Page 6: Installation Requirements

    3. Installation Requirements General Information In IE, the installation must be carried out by a competent person and installed in accordance with the current edition of: Delivery The unit is delivered in two packages (1) the boiler with I.S.813 “D ”.

  • Page 7: Electricity Supply

    Electricity Supply Cupboard or Compartment A cupboard or compartment used to enclose the boiler must be designed and constructed specifically for this purpose. An 230V ~ 50Hz via a fused double pole switch with existing cupboard or compartment may be used provided that a contact separation of at least 3 mm in both it is modified for the purpose.

  • Page 8: Condensate Disposal

    Condensate Disposal Termination via internal discharge branch e.g sink waste - downstream This boiler incorporates a 75 mm trap. Boiler Ensure the disposal of condensate complies with Pipe must terminate any national or local regulations in force. above water level but Sink below surrounding Failure to install the condensate disposal pipework...

  • Page 9: Air Supply

    Air Supply Flue Systems The room in which the boiler is installed does not require Horizontal a purpose provided air vent. The standard flue/terminal assembly can be cut and 3.7.1 Ventilated Cupboard/Compartment is suitable for an installed length from 160 mm up to 700 mm.
  • Page 10 Example Flue Layouts Maximum Equivalent Flue Resistance = 3.55 Metres 5111073 5111073 5111074 5111074 5111074 5111073 5111075 5111074 5111085 5111074 (pair) 5111073 5111085 5111074 (pair) 5111073 5111076 5111073 5111075 5111075 5111074 5111074 5111075 5111074 5111074 5111073 5111075 Fig. 8 Suprima HE intelligently applied technology...
  • Page 11 Flue Deflector Terminal Position with Minimum Distance (mm) For IE, refer to I.S. 813 "Domestic Gas Installation". We recommend the use of the Flue Deflector Kit (part no. 5111068) Fanned Draught Balanced Flue when:- Directly below an opening, air brick, •...

  • Page 12: Water Circulating Systems

    Water Circulating Systems To ensure correct circulation, it is essential to vent all air from the system prior to commissioning the boiler. The boiler is suitable for use with fully pumped open System Drain Off Points vented and sealed systems with an indirect coil type Drain off points should be fitted in the pipework close to high efficiency cylinder.
  • Page 13 3.9.5 Boiler Protection Suprima 30-80 HE hydraulic resistance • A frost thermostat is fitted within the boiler controls which operates even if the temperature control knob is at the ( ) position. The boiler will operate as necessary to maintain the boiler temperature above freezing.
  • Page 14 3.9.6 Sealed Systems The vessel size can now be determined from the information in Table 3 where V = System size in litres. System Components All components used in the sealed system must be Vessel Charge Pressure (bar) suitable for operation at 110°C and at the maximum pressure allowed by the pressure relief valve (normally Initial System Pressure (bar) 3 bar).
  • Page 15 Indirect HE Cylinder Auto air vent Pressure gauge visible from filling point Optional Safety Optional 2 port valve valves 3 port Pump with valve isolating valves Flow Automatic Expansion Alternative existing by-pass or vessel by-pass arrangement existing using the bathroom by-pass Auto air vent radiator fitted with two...

  • Page 16: Installation

    4. Installation Unpack & Prepare the Wall & Boiler Cut with MINIMUM CLEARANCE MINIMUM CLEARANCE 3° Rise Core Drill Flue Hole Centre Line Centre Line 105mm (4")minimum Flow Return These instructions assume you have chosen a Suprima HE 127mm (5") mimimum for Internal Publication No.

  • Page 17: Install The Flue

    Install the Flue Standard Horizontal Flue These instructions are for standard horizontal Minimum dimension X including wall rear and side flue applications which have a thickness = 160 mm maximum horizontal installed length of 700 mm Rear flue when fitted. Maximum dimension X = 700 mm When using bends and extensions the Wall seal...

  • Page 18: Electrical Connections

    Electrical Connections Typical System Wiring For the boiler to operate correctly it Optional Integral Programmer. requires a four wire connection - Mains supply wired direct to boiler terminal block. Pump wired direct to boiler terminal block. permanent live, neutral, earth and switched live.

  • Page 19: Connect The Gas Supply

    Connect the Gas Supply 1. Ensure that the gas supply is isolated at Gas cock Open the meter. 2. Solder the gas tail (supplied) to main gas supply before connecting the tail to the gas cock. Securing screws To prevent blow lamp damage to the wiring and condensate trap, any soldering of gas pipework must be done away from the boiler.

  • Page 20: Wiring Diagrams

    Earth to Burner Air Pressure Overheat Switch Stat Flow Thermistor Spark Valve Generator L N E SwL L N E Casting Mains Pump Thermistor Spark Flame Electrode Detection b - blue Electrode bk - black br - brown g/y - green/yellow or - orange p - purple y - yellow...
  • Page 21 Typical System Wiring - mid position valve (Y Plan) Typical System Wiring - two zone valves (S Plan) External Programmer External Programmer Mains supply direct to wiring centre The Pump can be wired through the wiring centre The Pump can be wired through the wiring centre but must be wired direct to Pump L, N &...

  • Page 22: Commissioning

    6. Commissioning 6.1 Commission the Water, Electrical and Gas 10.Turn the temperature control knob to ( ) position and check that the burner shuts down. Systems 11. Remove the pressure gauge, re-fit the screws and Water check for gas soundness. The system should be cold flushed.

  • Page 23: Final Adjustments

    6.4 Final Adjustments Temperature Control Turn the temperature control knob to adjust the radiator surface temperature and hot water tap temperature between approximately 63°C and 82°C. Overheat Thermostat The boiler will require re-setting if an overheat condition occurs (the ‘Lockout’ (Red) light will flash). Other Boiler Controls No further setting or checking is necessary as all boiler mounted controls are fail safe.

  • Page 24: Control Sequence

    7. Control Sequence STANDBY Flow temperature >100C PUMP Switched live - ON OVERHEAT LOCKOUT OVERRUN On/Off switch - ON (2 minutes) Check Indicate thermistor Fault thermistors give valid readings Flow temperature>100C Overheat stat OFF PUMP ON Ignition attempt fault Check thermistors Indicate thermistor Fault Casting thermistor fault read within 8C...

  • Page 25: Fault Finding Guide

    8. Fault Finding Guide Lockout Codes = off = flashing = on FAULT CONTROL DISPLAY RESET Lockout Burner Mains Electrical supply fault Lockout Burner Mains Ignition LOCKOUT Manual Lockout Burner Mains Overheat LOCKOUT Manual Lockout Burner Mains False flame fault Automatic Lockout Burner...
  • Page 26 Electrical Supply Fault Lockout Burner Mains This boiler requires a minimum of 195V to function. No Switched Live to boiler. Check systems controls and systems wiring. 230V at (A)? SwL L Check for shorts on Pump, Fan & Gas Valve. Replace if shorted &...
  • Page 27 Ignition Lockout Lockout Burner Mains Is more than 17mBar Incorrect gas supply to dynamic pressure at gas valve boiler inlet? 4 way connector that is part of the wiring harness Is Live & Viewed from non wired end Neutral to Correct Live &...
  • Page 28 Overheat Lockout Lockout Burner Mains Wait until the temperature at the flow pipe is <60C Unplug Check as the 8 way connector The 8 way Circulation Lockout fault that is part of the Connector from the PCB. wiring harness Is there continuity across (N)? Viewed from non wired end Remove...
  • Page 29 Circulation Lockout Lockout Burner Mains Adequate circulation is checked by a thermistor in the casting. To activate a lockout, this needs to trip 4 times during a call for heat. Fill System with water and bleed out all air Is the System full of water? Open bypass/TRV's Is there...
  • Page 30 Air pressure switch stuck Fault Lockout Burner Mains Viewed from non wired end Switch the boiler on. Replace PCB Replace the After Remove the 12 Way connector. Is there 15 seconds. 12 way connector Remove case. Remove one 230V at the two Does the fan run? from the PCB.
  • Page 31 Thermistor Fault Lockout Burner Mains There are two types of fault which can occur: 1) The thermistors are reading outside of limits. (This is checked before the PUMP is switched on and Flow thermistor fault during BURNER ON) 2) The difference between the thermistor readings are outside of limits.

  • Page 32: Servicing & Parts Replacement

    Condensate trap - remove if required, see 9.13. • Ensure you are using the correct Baxi Potterton Place a vessel underneath to catch the approved spare part when replacing any items as condensate then remove the trap drain plug.
  • Page 33 Return Connection Flow Connection Flow Sensor Overheat Sensor Casting Sensor Air Pressure Switch 'O' Ring and Clip Joints Fan and Flue Hood Secondary Heat Exchanger Primary Heat Exchanger Burner & Electrodes Data Label Wiring Centre PCB Enclosure Condensate Trap Gas Connection Gas Valve Spark Igniter Condensate Connection...

  • Page 34: General Access

    9. Parts Replacement 9.2 General Access 1. Isolate the supplies as detailed in 9.1.2. 2. Pull the door panel down and remove the two screws. Carefully slide the bottom cover out and away from the boiler. 3. Remove the three screws and carefully lift the outer case away from the boiler.

  • Page 35: Air Pressure Switch

    9.5 Air Pressure Switch Ease bracket open Disconnect tubes 1. Perform General Access - See 9.2. 2. Disconnect the wires at the switch. 3. Note how they are fitted then disconnect the sensing tubes at the switch. 4. Ease the front of the bracket forwards and carefully prise the switch out of the bracket.

  • Page 36: Fan & Flue Hood

    9.9 Fan and Flue Hood Warning 325V d.c a.c fan - 30 to 60 models Isolate the d.c. fan - 70 and 80 models mains supply. 1. Perform General Access - See 9.2. Sensing tubes 2. Remove the screw securing the front combustion chamber cover.

  • Page 37: Electrodes/Burner

    9.10 Electrodes/Burner 1. Perform General Access - See 9.2. 2. Remove the combustion chamber cover - Ignition electrode Sensing electrode See 9.9. Remove screw 3. Disconnect the ignition lead from the ignition electrode and the sensing lead and earth lead from the sensing electrode. If replacing electrode(s), remove securing screw(s) as appropriate.

  • Page 38: Combustion Chamber Insulation

    9.12 Combustion Chamber Insulation Important: See Section 3.1, Health and Safety information before handling insulation. 1. Perform General Access - See 9.2. 2. Remove the screw securing the front combustion chamber cover. Pull the cover out slightly then down to unhook and lift away from the boiler.

  • Page 39: Condensate Trap

    9.13 Condensate Trap 1. Perform General Access - See 9.2. Place a vessel underneath to catch the condensate then remove the drain plug. Take care as the condensate could be hot. Spring clip 2. Disconnect condensate disposal pipework from the flat faced union on the trap and swing pipework away from boiler.

  • Page 40: Primary Heat Exchanger

    9.14 Primary Heat Exchanger Screw Flue duct securing 1. Perform General Access - See 9.2. bracket 2. Drain the system as necessary. 3. Remove the combustion chamber cover - See 9.9. 4. Drain the heat exchanger, a drain point is located on the left hand side bottom of the Bolt Screw...

  • Page 41: Secondary Heat Exchanger

    9.15 Secondary Heat Exchanger 1. Perform General Access - See 9.2. 2. Drain the system as necessary. 3. Drain the Heat Exchanger - See 9.14, 4. Pipe clips 4. Remove the Spark Igniter - See 9.6. To ease removal of the secondary heat exchanger it may be necessary to:- Remove the Air Pressure Switch - See 9.5.

  • Page 42: Short Spares List

    10. Short Spares [60 - 80HE] [30 - 50HE] [60 - 80HE] [30 - 50HE] [70 - 80HE] [30 - 60HE] Fig. 44 Suprima HE intelligently applied technology...
  • Page 43 Drg. Ref. G.C. No. Description Part No. 114-852 Sight glass mica 238162 114-872 Mica retainer outer 238106 Fan and gasket kit 30 HE 5112318 Fan and gasket kit 40 HE 5112319 Fan and gasket kit 50 & 60 HE 5112320 Fan and gasket kit 70 &...
  • Page 44 All goods are sold subject to our standard Conditions of Sale which are available on request. B A X I P OT T E RTO N A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP Website www.potterton.co.uk company...

This manual is also suitable for:

Suprima40 heSuprima 50 heSuprima 60 heSuprima 30 heg.c. no. 41 075 35Suprima 60 heg.c. no. 41 075 38Suprima 70 heg.c. no. 41 075 39 ... Show all

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