Potterton Suprima 30, Installation And Service Instructions Manual

Page 1: ...hat 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 WITH THE USER FOR USE ON FUTURE CALLS For Use With Natural Gas G20 Only At 20mbar For Use in GB IE IMPORTANT ...

Page 2: ... G C No 41 607 78 Suprima 70 G C No 41 607 79 Suprima 80 G C No 41 607 80 The boiler model and serial number are given on the boiler data label which is located on the right hand side of the chassis and visible after opening the controls door 3 Commissioning 21 3 1 Commission the Boiler 22 3 2 Final Adjustments 23 3 3 Instruct the User 23 3 4 Advise the User 23 4 To Service the Boiler Component Re...

Page 3: ... Pressure 20mbar Gas Supply Connection Rc in BSP Female Maximum Flow Temperature 82ºC Flow Return Connections 22 mm Copper Water Content 1 6 litres 0 37 gal 30 40 50 60 Models 2 1 litres 0 46 gal 70 80 Model Appliance Lift Weight 26 0 kg 57 3 lbs 30 40 50 60 Models 30 2 kg 66 6 lbs 70 80 Model Appliance Weight Installed Dry 32 0 kg 70 0 lbs 30 40 50 60 Models 35 4 kg 78 1 lbs 70 80 Model Electrici...

Page 4: ...ts are available for the Suprima range of boilers see pages 14 15 1 Installation Requirements Page 4 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 quantities of adhesives and sealants used in the pro...

Page 5: ... 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 25 mm to combustible material A metal sleeve should be installed to surround the flue duct to provide a 25mm annular space Further guidance is given in ...

Page 6: ...Installation Requirements Page 6 ...

Page 7: ...e front of the boiler and the door for air movement 1 7 Flue Systems Horizontal The flue terminal assembly supplied is suitable for a wall thickness of between 150mm and 400mm A flue terminal assembly suitable for a wall thickness of up to 600mm is also available Both the flue terminal assemblies are telescopic and the minimum lengths 150 mm 6 in are achieved by cutting 1m flue extensions are avai...

Page 8: ... DWELLING VERTICALLY FROM A TERMINAL ON THE SAME WALL HORIZONTALLY FROM A TERMINAL ON THE SAME WALL VERTICAL FLUES ABOVE ROOF LEVEL TO BASE OF TERMINAL FROM ADJACENT WALL TO FLUE FROM INTERNAL CORNER TO FLUE BELOW EAVES OR BALCONY FROM FACING TERMINAL 30 60 300 25 25 25 25 25 300 600 1 200 1 200 1 500 300 300 210 230 600 1 200 70 80 300 25 25 25 25 100 300 600 1 200 1 200 1 500 300 300 210 230 600...

Page 9: ...ot be less than 15mm Pipework connecting the expansion vessel should not incorporate valves of any sort Methods of supporting the vessel are supplied by the vessel 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 ...

Page 10: ...Installation Requirements Page 10 Fig 3 Fig 4 ...

Page 11: ...e through them quoted in their manufacturers literature must be taken into account The pump may be fitted on either the flow or return and MUST be wired directly to the boiler terminal block It must be fitted with two isolating valves which are positioned as close to the pump as possible Closing of any valve must always leave the open vent unobstructed Water Flow Rate Boiler Resistance 30 40 50 60...

Page 12: ...Flue Kits Page 12 ...

Page 13: ...Optional Extras Flues Page 13 Installation instructions included as necessary with each kit ...

Page 14: ...System and Other Kits Page 14 ...

Page 15: ...System and other Kits Page 15 ...

Page 16: ...9 Insert wall plugs and secure the mounting bracket to the wall using two No 12 x 2 woodscrews 10 Lift the boiler onto the mounting bracket slide both boiler securing clips over the mounting bracket this prevents the boiler from being accidently lifted off the the mounting bracket see fig 7 11 The third screw provided is also to prevent the boiler from being lifted off the mounting bracket once th...

Page 17: ...t the seals are still correctly located 7 Hang the boiler onto the mounting bracket To square the boiler to the wall adjust the boiler alignment screws on the back panel of the boiler 8 Slide the flue back until it engages in the elbow bayonet connection twist anti clockwise to lock 9 Drill through pilot hole and lock flue in position with the self tapping screw provided 10 Make good the wall arou...

Page 18: ...ction 3 the terminal block and the cable clamp then Ensure sufficient slack is available to the cable clamps to allow the control panel to panel I section 2 4 performing steps 4 and 5 below Secure the controls assembly to the chassis using the screw previously removed Carry out preliminary electrical system checks i e Earth Continuity Short Circuit Polarity Frost Thermostat If a Frost Thermostat i...

Page 19: ... board 3 immediately below the programmer using the two screws provided 2 5 Connect the Gas Supply supply using a suitable adaptor to the gas cock Important assembled to the gas cock The pipe diameter required will depend on the boiler model supply pipe is selected in accordance with BS 6891 so that an adequate gas supply to the boiler is provided ...

Page 20: ...Installation Page 20 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 at the lowest points in the system ...

Page 21: ... Code Boiler Code No Model G C No 50 AHHP 601 0001 Input Q Gross Output P Gas Rate Burner Pressure Hot Cat C o u n t r y o f D e s t i n a t i o n G B I E kw kw mbar NG 20 mbar Type C C 12 32 2H 18 3 14 7 1 75 10 3 14 8 11 4 1 42 6 7 PMS 3 0bar G C No 41 607 77 8 7 AR XXXX IP20 Btu h Btu h ft h m h in wg Potterton Myson Ltd 503189 ISS 01 62500 50000 61 8 4 10 50500 39000 50 1 2 65 96 Injector Size...

Page 22: ...its maximum setting The boiler will attempt to light if the boiler does not light within 3 attempts due to air in the system the boiler controls will go to Lockout and the upper Red LED on the control panel will go to a rapid flashing mode To re start the lighting sequence press the reset button on the control panel There will be a short delay before the lighting sequence starts When the boiler bu...

Page 23: ...mbly Other Boiler Controls 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 External Controls Check that any other external controls connected in the system such as clocks or thermostats control the boiler as required 3 3 Instruct the User On completion of the installation the installer should demonstrate th...

Page 24: ...ace a sheet of paper under the heat exchanger then using a flat blade tool Part No 907736 scrape the flueway fin surfaces in a downward movement This will ensure that most of the deposits will be collected on the paper 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 gently to remove any debr...

Page 25: ...e access to the injector 9 Use a new sealing washer when re fitting the injector The heat exchanger burner and fan can now be inspected If deposits have formed on these items and on ancillary components clean as detailed in the notes at the start of this section The boiler can be re assembled in reverse order Ensure that any electrical connections are in place and that any damaged seals or insulat...

Page 26: ...he 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 assemble in reverse order ensure that the Normally Closed N C terminal is shrouded 4 3 3 Electrode Gain General Access See 4 1 1 Pull the electrode l...

Page 27: ...ccess 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 washer on re assembly If using a flat spanner to remove the injector See the next section 4 3 6 4 3 6 Combustion Chamber Insulation 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 ...

Page 28: ...nifold 4 3 7 Gas Valve 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 Remove the burner See 4 3 4 4 Remove the screw securing the controls assembly to the top of the valve 5 Remove the two screws securing the side and rear insulation assembly to the front of the chassi...

Page 29: ...or 3 Remove the two screws securing the fan to the flue hood 4 Carefully pull the fan down and away from the boiler 5 Flue Hood On re assembly ensure that the flue hood locates under the two brackets at the rear of the chassis Check the seal and replace if damaged 6 Fan On re assembly ensure that the rubber seal around the fan opening is located correctly into the base of the flue elbow 7 Re assem...

Page 30: ...t 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 4 3 10 Overheat Thermostat Gain General Access See 4 1 1 Disconnect the wires from the thermostat 2 Unscrew the thermostat 3 Re assemble in reverse order ...

Page 31: ...screw the drain screw Drain the heat exchanger 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 exchan...

Page 32: ...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 1 12 The control will continue to run the ...

Page 33: ...6 Wiring Diagram Page 33 ...

Page 34: ...mister shorted Turn OFF mains supply Are the two ORANGE wires to the Air Pressure Switch Shorted Check wiring Turn OFF mains supply Are the two WHITE wires to the Over heat thermostat Shorted Check wiring Boiler has not lit The control will attempt to light the boiler two further times before going to Lockout RED light flashing Is the Pump Live output at the terminal block Live Gas valve has remai...

Page 35: ...ble through the viewing window After 2 further ignition attempts does the RED LED flash Is the Electrode Gap correct 3 4mm and Lead O K Rectify or replace the Electrode and Lead as appropriate Replace Overheat Thermostat Is there 210v dc across the outer pins of the Gas Valve Connector whilst the GREEN LED is flashing rapidly 16Hz Replace Gas Valve Assembly Check Water Pump and associated wiring I...

Page 36: ...8 Short List of Spare Parts Page 36 ...

Page 37: ...bly 30 to 60 1 8409588 114 805 70 to 80 1 8409589 E01966 Fan Assembly 30 to 60 1 8409595 E01967 70 to 80 1 8409596 13 173 130 Overheat Thermostat 1 8404517 14 173 133 Injector Main Burner 30 1 8411021 173 134 40 1 8411022 173 135 50 1 8411023 173 136 60 1 8411024 173 137 70 1 8411025 173 138 80 1 8411026 15 337 862 Flue Scraper 1 907736 16 114 873 Front Panel Seal Type 1 1 8650691 16a 114 874 Fron...