Potterton Suprima 30 HE, Installation & Service Instructions Manual

Page 1: ...on Service Instructions Only a flue approved for the Suprima HE can be used These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Suprima 30 80 HE Condensing Central Heating Boiler ...

Page 2: ...ng appliance to the relevant Local Authority Building Control Department From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1 January 2006 CORGI operate a Self Certification Scheme for gas heating appliances These arrange...

Page 3: ...rtificate of compliance to the property You must ensure that the notification number issued by CORGI is writen onto the Benchmark Checklist Scheme Members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days If you notify via CORGI Scheme CORGI will then notify the relevant Local Authority Building Control Scheme on member s behalf Complete the Benchmark Checklist Inst...

Page 4: ...ully pumped open vented and sealed systems with an indirect coil type high efficiency cylinder The gas type supply size and pressure must be checked for suitability before connection Failure to install the condensate discharge pipework correctly could affect the reliable operation of the boiler For the boiler to operate correctly all air must be vented from the system prior to commissioning and th...

Page 5: ...eral fibre b Prolonged or excessive exposure to this material may result in some irritation to the eyes skin or respiratory tract c It is advisable to wear gloves when handling these items d Irritant dust will only be released from the items if they are broken up or subjected to severe abrasion In these instances a suitable dust mask and goggles should be worn e Always thoroughly wash hands after ...

Page 6: ... 20 20 20 20 20 20 Injector Size mm 2 8 3 1 3 5 3 9 3 9 4 1 Water Content litres 2 3 30 40 50 2 7 60 70 80 Boiler Weight kg 39 0 30 40 50 42 8 60 70 80 Lift Installed Dry Nox Class 2 2 2 2 2 2 Maximum Working Head 30 5m 100 ft Minimum Working Head 150mm 6 in Flow Temperature Range 63 C 82 C Gas Supply Connection 15 mm Tail Flow Return Connections 22 mm Copper Condensate System Connection 21 5 mm P...

Page 7: ... mm 770 mm overall clearance Fan and Flue Hood Air Pressure Switch Secondary Heat Exchanger Condensate Trap 75 mm Gas Valve Primary Heat Exchanger PCB Enclosure Burner Electrodes Flow Connection Return Connection Spark Igniter Flow Sensor Overheat Sensor Casting Sensor 610 mm servicing clearance 260 mm 15 mm clearance Condensate Connection Wiring Centre Data Label O Ring and Clip Joints Gas Connec...

Page 8: ...land The WATER FITTINGS REGULATIONS OR WATER BYELAWS in Scotland The I E E WIRING REGULATIONS Where no specific instructions are given reference should be made to the relevant BRITISH STANDARD CODES OF PRACTICE Reference should also be made to BRITISH GAS GUIDANCE NOTES FOR THE INSTALLATION OF DOMESTIC GAS CONDENSING BOILERS Definition of competence A person who works for a CORGI registered compan...

Page 9: ...loser than 25 mm to combustible material A metal sleeve should be installed to surround the flue duct to provide a 25 mm annular space Further guidance is given in BS5440 Pt 1 Timber Frame If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institution of Gas Engineers Publication IGE UP 7 Gas Installation in Timber Frame...

Page 10: ...ay force water out of the boiler trap and could affect the operation of the boiler 5 Any condensate pipework external to the building or in an unheated part of it e g garage should not exceed 3 metres in length and when in an exposed position waterproof insulation is recommended It is also recommended that the pipe diameter is increased to 32 mm If the boiler is fitted in an unheated location the ...

Page 11: ...table for an installed length from 160 mm up to 700 mm 1 m flue extensions are available Maximum straight flue length 3 55 m 3 extensions equivalent resistance 3 55 m It is recommended that the flue is supported at least once per metre All lengths quoted exclude the boiler elbow Example layouts are shown on the Page 12 Bends A 93 bend is equivalent to a 1m length of flue A 135 bend is equivalent t...

Page 12: ...5111074 5111085 pair 5111073 5111075 5111074 5111074 5111075 5111073 5111074 5111075 5111074 5111075 5111073 5111073 5111073 5111076 5111074 5111074 5111073 5111074 5117381 5117382 5117380 Plume Displacement 60 100 dia Kit Kit No 5117379 Fig 8 Example Flue Layouts Maximum Equivalent Flue Resistance 3 55 Metres ...

Page 13: ...earer than 150 mm to an opening in the building fabric formed for the purpose of accommodating a built in element such as a window frame See BS 5440 Pt 1 N I I G F M I A A F H J K D E H Likely flue positions requiring a flue terminal guard C R I J K I L T S B Fig 9 300 300 300 We recommend the following terminal guards Tower Flue Components Ltd Tower House Vale Rise Tonbridge Kent TN9 1TB Tel 44 1...

Page 14: ...itted within the system pipework to prevent air locks during filling commissioning and normal operation To ensure correct circulation it is essential to vent all air from the system prior to commissioning the boiler System Drain Off Points Drain off points should be fitted in the pipework close to the boiler and in the low points of the system Plastic Pipework If plastic pipe is used for the centr...

Page 15: ...nal 3 port valve Auto air vent 150 mm Max Boiler drain off point inside casing Pump with isolating valves Table 2 3 9 5 Boiler Protection 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 The boiler is fitted with a timed pump overrun t...

Page 16: ...tion 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 Boiler Heat Exchanger 2 7 litres Small Bore Pipework 1 litre per kW of system output Micro Bore Pipework 7 litres Steel Panel Radiators 8 litres per kW of system output Low Water Capacity Radiator...

Page 17: ...tions including any branches Specification of all components 110 C and 3 bar 2m Automatic by pass or existing by pass balancing valve Optional 3 port valve Auto air vent Pressure gauge visible from filling point Safety valve Expansion vessel Alternative existing by pass arrangement using the bathroom radiator fitted with two lockshield valves Pump with isolating valves Manual Filling and Make Up P...

Page 18: ...ottom Mounting Points BOILER SECURING POINT Drill and plug 7 mm Secure using woodscrew supplied or optional Anti theft kit WALL MOUNTING BRACKET Drill and plug 7 mm Secure using woodscrews supplied 50mm per metre 2 5 Minimum Fall Boiler Mounting Bracket Boiler Mounting Bracket Woodscrews Boiler Securing Point Woodscrew or Anti theft kit Lifting points in base of packing Fig 13 4 Installation 4 1 U...

Page 19: ... screws Ensure all flue elbow seals are still correctly located If using a left hand side flue application we recommended you make the flow and return water connections before fitting the flue 1 Measure dimension X from the centre point of the flue elbow to the outside of the wall and add 50 mm 2 Mark the dimension to be cut onto the flue as shown Re check measurements and ensure the inner flue su...

Page 20: ...3 If fitting the optional integral programmer Part No 5111963 do so as described in the kit 4 Carry out preliminary electrical system checks i e Earth Continuity Short Circuit Polarity and Resistance to Earth For safety leave the electrical supply switched off and isolated until boiler installation is complete See Page 23 for typical system wiring Optional Potterton Integral Programmer Schematic w...

Page 21: ...Compression fittings must be used to allow future disconnection We recommend using two spanners when making the connections Heat from a blowlamp could damage the case seals 4 6 Connect the Condensate System 1 The condensate connection is a 21 5 mm PP pipe To allow access for servicing we recommend the first connection to the system is a push fit type 2 Prime the condensate system to seal the trap ...

Page 22: ...ctrode Flame Detection Electrode Fan Gas Valve Flow Thermistor Casting Thermistor Air Pressure Switch Earth to Burner L N E SwL L N E Mains Pump g y g y g y g y g y g y b br y r b w p p br b bk bk bk r bk y y b b or or b blue bk black br brown g y green yellow or orange p purple y yellow r red w white Boiler Wiring Fig 19 ...

Page 23: ...he Pump can be wired through the wiring centre but must be wired direct to Pump L N Earth on boiler terminal block b blue br brown g y green yellow Boiler PCB NC C N HW on E HW off L CH on Pump Mains T h i s A p p l i a n c e m u s t b e E a r t h e d N N L E E SwL L 7 8 9 4 10 5 E N L 1 7 2 8 3 9 4 10 5 6 6 11 11 12 12 Optional external programmer Fused 3A Mains Supply Frost stat Not used Typical...

Page 24: ...sure burner pressure and gas rate are correct See data label or refer to Page 6 If adjustment of the burner pressure is required follow Section 9 4 8 Check that the burner flames are blue and stable 9 Turn the temperature control knob to position and check that the burner shuts down 10 Remove the pressure gauge re fit the screws and check for gas soundness 11 Re fit the controls cover assembly and...

Page 25: ...ration of the boiler and its associated controls Advise the user of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frost conditions Advise the user that this boiler has frost protection pump overun and pump anti seize features See 3 9 4 Advise the User that for continued efficient and safe operation of the boile...

Page 26: ...verheat stat Off Overheat Lockout Run Check casting thermistor 80C Casting temp exceeded 4 times APS On Flame On Air Proving Lockout APS Off 4 times in 15 mins Circulation Lockout Indicate APS fault Safety shutdown 5 mins Overheat stat Off Check thermistors give valid readings Switched live On On Off switch On Overheat Lockout Check flow thermistor casting thermistor Flow temperature setpoint Post...

Page 27: ...er Mains Overheat LOCKOUT Manual Lockout Burner Mains Water Circulation LOCKOUT Manual Lockout Burner Mains Air Proving LOCKOUT Manual Lockout Burner Mains PCB Fault Replace PCB Automatic Lockout Burner Mains False Flame Fault Automatic Lockout Burner Mains APS Stuck Fault Automatic Lockout Burner Mains Flow Thermistor Fault Automatic Lockout Burner Mains Casting Thermistor Fault Automatic off fla...

Page 28: ...nent Live to boiler Check systems controls and system wiring Is terminal block fuse OK Check for shorts on pump fan and gas valve Replace if shorted and replace fuse No No This boiler requires both a permanent live and a switched live Both need to be a minimum of 190V to function Yes Check wiring from terminal block to PCB No Replace PCB Yes Is there 230V at 6 way plug to PCB Mains L and N off off...

Page 29: ...No Yes Replace gas valve Yes Replace PCB Lead from PCB to gas valve faulty Yes Does flame establish and then extinguish Is flame detection electrode damaged No Is wiring to the detection electrode OK Yes Yes Replace electrode No Set gap to correct position over falme strip No Rectify wiring No Is there a spark Is spark electrode damaged Is the electrode gap between 3 and 4 mm No Is wiring from spa...

Page 30: ...un period Note An unstable flame will cause intermittent problems Wait until the temperature at the flow pipe is 60C Check as the Water Circulation Lockout fault Unplug the 8 way connector from PCB Is there continuity between the 2 black wires Replace the overheat thermostat Remove connectors from overheat thermostat Is there continuity across the terminals Wiring faulty between the PCB and the ov...

Page 31: ...rculation is checked continuously during burner fire If the casting thermistor exceeds 80C the fault occurs A lockout is activated if this happens 4 times Water Circulation Lockout Refer to the boiler wiring diagram Yes No Fill system with water and bleed out all air Is the system full of water Yes No Is the pump running Yes No Reset lockout Is there 230V at the terminal block Pump L and N Pump or...

Page 32: ...oiler on Does fan run Replace PCB Yes Replace fan Yes Unplug the APS leads Is there continuity across the the APS APS stuck in the On position Replace Short circuit on the wiring rectify No Yes Rectify fault Switch off Unplug the 12 way connector and both APS leads Is there continuity between the 2 orange wires Open circuit on the APS wiring rectify Yes Check the tubes from venturi to the APS Chec...

Page 33: ...tween 0 5kΩ 20kΩ and within 25 of each other Remove connectors from the thermistors Measure resistance of thermistors Do resistances vary from ones previously measured Wiring from PCB to thermistor faulty Replace Faulty Thermistor This can be identified by removing both thermistors and holding the brass probe between your fingers The resistance should be approximately 8kΩ There are two types of fa...

Page 34: ...nd carefully clean if necessary Check the condition of the sensing tubes at the Fan and Air Pressure Switch c Burner remove if required see 9 10 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 gently to remove any debris Protect the electrodes d Electrodes remove if required see 9 10 If the electro...

Page 35: ...econdary Heat Exchanger Condensate Trap Gas Valve Primary Heat Exchanger PCB Enclosure Burner Electrodes Flow Connection Return Connection Spark Igniter Flow Sensor Overheat Sensor Casting Sensor Wiring Centre Data Label Condensate Connection O Ring and Clip Joints Gas Connection Flue Sample Point Fig 30 ...

Page 36: ...k by unscrewing the four long hexagonal head screws from the side of the valve Note Loosen the condensate trap securing screws to improve access to the gas valve 4 Using the service spanner supplied with the new valve remove the front screw and loosen the two rear screws securing the gas valve to the manifold 5 Slide the valve backwards and carefully remove from the boiler 6 Re assemble in reverse...

Page 37: ...ng screws slide unit back to clear screws and lift away from the boiler 4 Disconnect the electrical plug Disconnect ignition lead if required 4 Re assemble in reverse order 9 7 Flow Casting Sensors 1 Perform General Access See 9 2 2 Disconnect the electrical plug from the sensor and unscrew the sensor from the pocket 3 Re assemble in reverse order Use a heat sink compound on the sensor shaft inser...

Page 38: ...r screws securing the fan to the flue hood and the screw securing the venturi to the fan 8 On re assembly Remove all traces of gasket from the flue hood then attach new gasket Fit the fan to the flue hood and secure using four screws previously removed Fit the venturi assembly to the replacement fan Ensure that the flue hood locates under the clips at the rear of the chassis The front of the flue ...

Page 39: ... electrodes onto replacement burner before re fitting 6 Re assemble in reverse order Check that the gap between the electrode tip and the burner face is 3 4 mm adjustment can be made by careful use of pliers 9 11 Injector 1 Remove the Burner See 9 10 Use a 13 mm A F or 1 2 A F socket spanner to remove the injector 2 Unscrew the injector 3 Re assemble in reverse order Use a new sealing washer on th...

Page 40: ...3 Remove the Burner See 9 10 4 Remove the two screws securing the side and rear insulation assembly to the front of the chassis 5 Pull the assembly forwards and away from the boiler Replace insulation pieces as required replace any securing clip if damaged 6 Re assemble in reverse order ensure the insulation assembly has located correctly over the tabs at the rear of the casing below the casting a...

Page 41: ...clip securing the rubber tube to the base of the sump 4 Loosen the left hand and remove the right hand screw securing the trap to the boiler 5 Slide the trap to the right to release from the left hand screw then pull the unit complete with tube down and away from the boiler 6 Re assemble in reverse order using a new case seal Pour half a litre of water into the trap to prime it before re fitting E...

Page 42: ...ompression fitting above the boiler Remove the clip securing the return pipe from the secondary to the primary heat exchanger 9 Release the flow and return unions at the heat exchanger and lift the pipes clear 10 Remove the screw from the top right hand side and bolt and nut from the left hand side mounting brackets 11 Support the heat exchanger spring out the left hand mounting bracket to clear t...

Page 43: ...mp forwards to remove from boiler 9 Support the heat exchanger then remove the screw and front supporting bracket 10 Manoeuvre the heat exchanger out to disconnect the gaitor and flue duct from the hood pull down to release the pipe O ring connections and lift away from the boiler 11 Check and replace seals washers O rings etc as necessary Lubricate O rings prior to fitting 12 Re assemble as follo...

Page 44: ...tly applied technology Baxi Heating UK Limited 2005 10 Short Spares Fig 44 308 322 305 313 207 331 200 30 60HE 206 60 80HE 206 30 50HE 216 30 50HE 216 60 80HE 200 70 80HE 217 306 332 329 330 318 202 219 121 120 209 ...

Page 45: ... to 50 HE 1 238244 114 856 Burner sub assembly 60 to 80 HE 1 238246 217 E78 614 Electrode 2 407776 219 Condensate trap assembly 1 5111451 305 PCB assembly 1 5110550 306 364 866 Temperature control knob 1 230981 308 Igniter assembly 1 5111922 313 Air pressure switch 30 HE 1 5112195 Air pressure switch 40 HE 1 5112196 Air pressure switch 50 HE 1 5110350 Air pressure switch 60 HE 1 5112197 Air pressu...

Page 46: ...E OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATI...

Page 47: ...INEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE INTERVAL RECORD It is recommended that yo...

Page 48: ... sold subject to our standard Conditions of Sale which are available on request General Enquiries GB Tel 08706 060 780 Technical GB Tel 08706 049 049 Service GB Tel 08706 096 096 Fax 01926 410 006 Literature Request GB Tel 08706 060 623 Technical IE Tel 1850 560570 Publication No 5111596 Iss 03 01 2006 Baxi Heating UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP After Sales Serv...