Potterton Suprima 100L, Installation & Service Instructions Manual

Page 1: ...tions 1998 Inyourowninterest andthatofsafety itislawthatallgasappliancesareinstalledbycompetent 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 LeavetheseinstructionsandtheBenchmarkLogBookwiththeuserforuseonfuturecalls Installation ...

Page 2: ...GasValve100 28 4 3 11Injectors100 29 4 3 12Fan FlueHood 29 4 3 13TemperatureSensor 30 4 3 14OverheatThermostat 30 4 3 15HeatExchanger 31 5 FunctionalWiringDiagram 32 6 WiringDiagrams 33 7 FaultFinding 34 8 ShortListofSpares 36 FlueKits 38 SystemandOtherKits 40 Potterton is a member of the Benchmark initiative and fully supportstheaimsoftheprogramme Benchmarkhasbeen introduced to improve the standa...

Page 3: ...5 23 4 28 7 Btu h 30000 40000 50000 60000 70000 80000 98000 Output kW 11 0 14 7 18 3 22 0 25 6 29 3 35 9 Btu h 37500 50000 62500 75000 87500 100000 122500 in wg 3 70 4 50 4 10 3 70 5 35 5 56 5 54 m h 1 05 1 40 1 75 2 10 2 45 2 80 3 42 ft h 37 1 49 3 61 8 74 2 86 4 98 7 120 9 Injector Size mm dia 2 8 3 1 3 5 3 9 3 9 4 1 3 2 30 40 50 60 70 80 100 mbar 9 3 11 2 10 3 9 2 13 4 13 9 13 6 SAFETY PERFORMA...

Page 4: ...inal assembly See pages 38 39 for flue options Various kits are available for the Suprima range of boilers see pages 40 41 1 Installation Requirements 1 1 Health and Safety Information for the Installer and Service Engineer Under the Consumer Protection Act 1987 and Section 6 of the Health and Safety at Work Act 1974 we are required to provide information on substances hazardous to health Small qu...

Page 5: ...e of air across it at all times The boiler must be mounted on a flat wall which is sufficiently robust to take the weight of the boiler The boiler is suitable for installation to a combustible wall e g wood cladding provided that the flue duct is not closer than 25mmtocombustiblematerial Ametalsleeveshouldbeinstalledtosurroundtheflueducttoprovidea25mmannularspace Further guidance is given in BS544...

Page 6: ...Supplied By www heating spares co Tel 0161 620 6677 Publication No 5102696 6 InstallationRequirements Fig 1 ...

Page 7: ...s are present within the compartment Maximum Horizontal flue length from turret 560 mm Minimum clearances for alternative configurations Front 280 mm or Front 490 mm Side 75 mm Side 175 mm Bottom 250 mm Bottom 100 mm Top 450 mm Top 265 mm 1 7 Flue Systems Horizontal The flue terminal assembly supplied is suitable for a wall thickness of between 150 mm and 300 mm A flue terminal assembly suitable f...

Page 8: ...cedFlue A Directly below an opening air brick opening window etc B Above an opening air brick opening window etc C Horizontally to an opening air brick opening window etc D Below a gutter or sanitary pipework E Below the eaves F Below a balcony or carport roof G Above ground roof or balcony level H From vertical drain soil pipe work J From an internal or external corner K From a surface facing a t...

Page 9: ... valves is shown in Fig 5 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 screw pos...

Page 10: ...andmake upunitasshown in Figs 3 4 MainsConnection There shall be no connection to the mains water supply or tothewaterstoragetankwhichsuppliesdomestichotwater eventhoughanon returnvalve withouttheapprovalofthe Local Water Authority Filling Point The system shall be fitted with a filling point at low level which incorporates a stop valve to BS 1010 and a double check valve of an accepted type to be...

Page 11: ...Supplied By www heating spares co Tel 0161 620 6677 Publication No 5102696 11 Fig 5 Fig 6 InstallationRequirements ...

Page 12: ...leave the open vent unobstructed Water Flow Rate Boiler Resistance l min 11 5 15 2 19 2 22 9 26 7 30 5 37 4 mbar 17 5 35 3 44 9 59 5 80 9 105 3 147 0 m 0 18 0 36 0 46 0 61 0 83 1 08 1 50 30 40 50 60 70 80 100 2 Installation 2 1 Unpack Prepare the Boiler These instructions assume you have decided on where the boiler will be located and the type of flue system to be used 1 Carefully unpack the boile...

Page 13: ...revent the boiler from being lifted off the mounting bracket once the boiler is mounted on the wall This screw can be replaced by an anti theft kit see note below Note Thereisprovisionforananti theftsecuring point sales code SUPKITP which may be used if required 2 2 Install the Flue Maximum equivalent flue lengths are as follows 30 80 Models 3 4m 100 Model 0 68m no bends allowed These instructions...

Page 14: ...mbinedwithaStandardFlueasshownbelow in the Maximum Flue Length Guide If a in line bend is required in the flue the following rules apply A 90 in line bend is the equivalent to a 1m length of flue A 135 in line bend is the equivalent to a m length of flue The maximum equivalent flue resistance allowed when using bends is 30 80models 3 4m 100model notallowed Note For flue lengths less than the minim...

Page 15: ... length of the earth wire is such that if the power supply cable pulls out of the cable clamp the live and neutral wires become taut before the earth wire 2 The pump wiring should be routed through the hole in the base of the rear cover through the cable clamp and connected to the terminal connection 3 Takeupexcessslackinthecablesbetween the terminal block and the cable clamp then tighten the cabl...

Page 16: ...ing do not solder the fitting whilst assembled to the gas valve The pipe diameter required will depend on the boiler model and the pipe length from the gas meter Ensure that the gas supply pipe is selectedinaccordancewithBS6891sothatan adequate gas supply to the boiler is provided Do not turn the gas supply on at this stage Front View 28 20 100 SUP0021B 40 85 28 Gas Valve All Dimensions in mm When...

Page 17: ...7 Publication No 5102696 17 Fig 12 Installation 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 ...

Page 18: ... cu ft h Output P Burner Pressure HOT Gas Rate Injector Size 2 8mm Dia Type C C C PMS 3 0 bar 230V 50Hz 80W 3A Fuse THIS APPLIANCE IS INTENDED EXCLUSIVELYTO BE INSTALLED ON A SUPPLY WITH A GOVERNED METER Baxi Heating Ltd 5105714 COUNTRY OF DESTINATION GB IE 01 0086 IP 20 NO x CLASS 3 9016 BOILER CODE No ALVG101 0003 SUPRIMA 30 L 12 32 2H 2H G20 20 mbar 71 30 L Model Shown 50 L Model Shown Gas Valv...

Page 19: ...n checking for gas soundness open all windows and doors in the room Extinguish all naked lights cigarettes pipes etc Important The commissioning and boiler adjustment must only be carried out by a suitably qualified personnel Potterton offer this service on a chargeablebasis Gas Pressure adjuster 100 model shown ...

Page 20: ...tted is in an On position and that the room and cylinder thermostat where fitted are set to high temperatures First time lighting 7 Set the temperature control knob to its maximum setting The boiler will attempt to light if the boiler does not light within 3 attempts due to air in the system theboilercontrolswillgoto Lockout andthe upper Red LED on the control panel will go to a rapid flashingmode...

Page 21: ...erheatThermostat Theoverheatthermostatispre setandnoadjustment is possible It will require manual re setting if an overheatconditionoccurs theLEDwillgotoflashing Red There setbuttonislocatedonthecontrolsassembly Commissioning OtherBoilerControls No further setting or checking is necessary as all boiler mounted controls are designed so that if a fault should occur they will fail safe ExternalContro...

Page 22: ...n Cleaning Boiler Components Heat Exchanger Place a sheet of paper under the heat exchanger then using a flat blade tool Part No 907736 scrape thefluewayfinsurfacesinadownwardmovement Thiswillensurethatmostofthedepositswillbecollectedonthepaper Burner Brush the burner top and check that the flame ports are clear Any blockage may be removed with a fine wire brush Turn the burner upside down and tap...

Page 23: ...anyelectricalconnections are in place and that any damaged seals or insulation are replaced before re fitting the controls cover Check the gas pressure refer to Section 4 3 7 30 80 or 4 3 10 100 OtherComponents No other servicing is required on any other boilercomponent 4 3 Component Replacement see over page Warning Before attempting to remove any component from the appliance first disconnect the...

Page 24: ...ee 4 1 1 Remove the securing screw and allow the control panel to pivot forwards 2 Note the wire connections and disconnect the wires to the air pressure switch 3 Remove the screw access through the fan compartment securing the air pressure switch to the chassis 4 Re assembleinreverseorder 4 3 3 Electrode Gain General Access See 4 1 1 Pull the electrode lead off the electrode remove the securing s...

Page 25: ... front 2 4 3 5 Injector 30 80 models Gain General Access See 4 1 1 Remove the burner See 4 3 4 2 Use a 13mm A F or A F socket spanner to remove the injector 3 Unscrew the injector use a new sealing washeronre assembly Ifusingaflatspannertoremovetheinjector see the next section 4 3 6 4 3 6 Combustion Chamber Insulation 30 80 models Gain General Access See 4 1 1 The front insulation is accessible as...

Page 26: ...the front of the chassis and remove assembly 6 Remove the three screws securing the gas valvemanifoldassemblytothechassisand remove the complete assembly 7 Remove the three M5 x 16mm screws securing the gas manifold to the gas valve 8 Use a new O ring and refit the manifold to the new gas valve 9 Re assemble in reverse order use a new side panel gasket and O ring in the gas cock 10 Check that the ...

Page 27: ...he burner onto the support tab on the side insulation Hook the rear of the locating bracket 2 in place beforelocatingthefront 3 andre fittingthe screw 4 3 9 Combustion Chamber Insulation 100 model Gain General Access See 4 1 1 The front insulation is accessible as the front is already off 2 Remove the burner See 4 3 8 3 Remove the two screws securing the side and rear insulation assembly to the fr...

Page 28: ...curing the side and rear insulation assembly to the front of the chassis and remove assembly 5 Remove the three screws securing the gas valve manifold assembly to the chassis and remove the complete assembly 6 Remove the four screws securing the gas manifold to the gas valve 7 Use a new O ring and refit the manifold to the new gas valve 8 Re assemble in reverse order use a new O ring in the gas co...

Page 29: ... 1 Disconnect the tube from the front of the fan housing note how it fits 2 Disconnect the wires from the fan motor 100 model only loosen the baffle plate securingscrewandremovethebaffleplate 3 Remove the three screws securing the fan to the flue hood 4 Carefully pull the fan away from the boiler 5 Flue Hood On re assembly ensure that thefluehoodlocatesunderthetwobrackets at the rear of the chassi...

Page 30: ... 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 4 3 14 Overheat Thermostat Gain General Access See 4 1 1 Disconnect the wires from the thermostat 2 Unscrew the thermostat 3 Re assembleinreverseorder To Service the Boiler Component Replacement Fig 22 ...

Page 31: ...texchangerandre tighten the plug 5 Remove the screws securing the combustion chamber insulation assembly to the chassis and withdraw it 6 Release both the flow and return nuts at the top of the heat exchanger 7 Support the heat exchanger remove the four bolts Two each side and carefully remove the heat exchanger 8 Replace rubber seals in flow and return ports feed the new heat exchanger into posit...

Page 32: ...air pressure switch proves fan is on 7 Gas valves open and ignition for 3 seconds green light flashes rapidly 8 Boiler firing green light On only 9 If the flame is not detected at this time the boiler will turn off 10 The above sequence will repeat for a further two ignition attempts before going to lockout indicated by the red light flashing 11 Pressing the reset button will re start boiler at No...

Page 33: ...Supplied By www heating spares co Tel 0161 620 6677 Publication No 5102696 33 WiringDiagram 6 Wiring Diagram Fig 25 ...

Page 34: ...ndicates a call for heat to the user 3 Control thermostat set to call for heat 4 Control starts ignition sequence Air Pressure Switch is checked for open circuit 5 Fan is energised 6 If APS fails to operate control goes to Blocking error Red light flashes but no need to press reset Control waits for APS to operate before energising gas valve and starting EHT spark 7 Control checks gas valve is ene...

Page 35: ...Supplied By www heating spares co Tel 0161 620 6677 Publication No 5102696 35 FaultFinding ...

Page 36: ...Supplied By www heating spares co Tel 0161 620 6677 Publication No 5102696 36 8 Short List Of Spare Parts Short List Spare Parts Fig 26 ...

Page 37: ... 100 models 40model 50model 80model Fan Assembly 30 to 40 models 50model 60 to 70 models 80model 100model OverheatThermostat Injector Main Burner 30 40 50 60 70 80 100 FlueScraper Front Panel Seal Type 1 Front Panel Seal Type 2 Front Panel Seal Type 3 Fan Outlet Seal Flue Tube Elbow Seal TemperatureSensor Fan Gasket 30 to 50 60 to 100 Fuse Type 3 15AT Electrode Lead 30 80 models Electrode Lead 100...

Page 38: ...Supplied By www heating spares co Tel 0161 620 6677 Publication No 5102696 38 Flue Kits Optional Extras Flues Fig 27 Check availability of these kits before ordering ...

Page 39: ...ff A E D F B Wall Plate Pack Sales Code SUPKITB Concentric Vertical Flue Adaptor Kit Sales Code SUPKITC Not 100 models B D C A D A E E B C Telescopic In Line Bend Adaptor Sales Code SUPKITR Not 100 models Terminal Guard Sales Code PTERMGUARDEF Internal Fitment Kit Sales Code SUPKITA C B A A Pitched Roof Flashing Kit Sales Code PUMAKITL SUP0038D Min Offset Flue Kit Sales Code 3SUPKIT A Terminal Elb...

Page 40: ...ith each kit Top Feed System Pipework only for SUPSYSKIT Sales Code SUPSYSKITTOP System Pod Kit Sales Code SUPSYSPODA Internal Fitment Kit Pod Kit Isolation Cock SUPSYSPODB Pod Kit only SUPSYSPODC Pod Kit Isolation Cock Instructions Junction Box Bracket Divertor Valve Pipework 22mm Pipework 22mm Nut Olive Wall Template Expansion Vessel Instructions System Case Instructions Flexible Hose SUP0248A R...

Page 41: ...w Head Suitable For Crosshead Screwdriver No 3 F R Installation instructions included as necessary with each kit Boiler Mounting Bracket Stand Off Frame Boiler Securing Screw 122mm Removeable Panel For Side Flue Outlet Boiler Stand Off Kit Sales Code SUPKITJ Programmer Kit Sales Code SUPKITH Optional Extras General Fig 30 Check availability of these kits before ordering ...

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Page 44: ...d but we reserve the right to make changes and improve mentsinourproductswhichmayaffecttheaccuracyoftheinformation contained in this leaflet All goods are sold subject to our standard ConditionsofSalewhichareavailableonrequest Toaidcontinuousimprovementandstafftraining callstothis linemaybemonitoredorrecorded General Enquiries Tel Technical Tel Service Tel Fax Literature Request Tel Publication No...

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Page 81: ...ce The appliance should have the following minimum clearances for Safety and Maintenance 15 mm at the front 610 mm for servicing access 5 mm each side 50 mm at the bottom and 125 mm above the case Flammable materials must not be stored in close proximity to the boiler Ensure that the flue terminal outside the house does not become obstructed particularly by foliage Potterton is a member of the Ben...

Page 82: ... the boiler simply turn the boiler thermostat to the required setting and switch the programmer ON To Shut Off Long Periods Turn the boiler thermostat knob to O Standby isolate the electrical supply at the isolating switch or pull the electrical plug out of the wall socket Important Read the section on Frost Precaution Temperature Control This enables you to control the temperature of the water as...

Page 83: ...ving checked these points run through the lighting procedure once more and if the boiler still fails to light call in your Service Engineer Frost Precautions If your boiler has to be shut down for several hours or more during very cold weather it may be in danger of freezing due to its position i e it may be in an outhouse or part of the pipework may be vulnerable to frost To avoid freezing variou...

Page 84: ... cannot accept any liability for expenditure or work done by other parties without our knowledge and or approval 3 Safety Check Routine Maintenance Itisstronglyrecommendedyouhaveyourboilercheckedannually for safety and for routine maintenance This should be carried out by a CORGI Registered Installer Service Agent or Potterton Service Operations to comply with the requirements of the Gas Safety In...

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