Potterton Suprima 100 Installation & Service Instructions Manual Download Page 1

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Installation & Service Instructions

Suprima 100

Wall Mounted Fan Assisted

Balanced Flue Gas Boilers

THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1994 (as amended).

‘‘ 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 WITH THE USER FOR USE ON FUTURE CALLS

For Use With Natural Gas
(G20) Only At 20mbar
For Use in GB & IE

IMPORTANT

PLEASE READ THIS BOOK
BEFORE INSTALLING,
OPERATING OR SERVICING
THIS BOILER.

Summary of Contents for Suprima 100

Page 1: ...e 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 PLEASE READ THIS BOOK BEF...

Page 2: ... Service the Boiler Component Replacement 22 4 1 General Access 22 4 2 To Service the Boiler 23 4 3 Component Replacement 23 4 3 1 Electronic Control Board 24 4 3 2 Air Pressure Switch 24 4 3 3 Electrode 24 4 3 4 Burner 25 4 3 5 Combustion Chamber Insulation 25 4 3 6 Gas Valve 26 4 3 7 Injector 27 4 3 8 Fan Flue Hood 27 4 3 9 Temperature Sensor 28 4 3 10 Overheat Thermostat 28 4 3 11 Heat Exchange...

Page 3: ...ght 34 6 kg 76 3 lbs 100 Model Appliance Weight Installed Dry 39 7 kg 87 5 lbs 100 Model Electricity Supply 230v 50Hz Fused at 3A Internal Fuse Type 3 15AT Power Consumption 80 Watts excluding pump Classifications CAT 12H C12 C32 IP20 SAFETY PERFORMANCE QUALITY Suprima boilers have been assessed by a Government appointed Notified Body and shown to meet the Essential Requirements of the European Ga...

Page 4: ...ma 100 see page 13 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 product are cured and present no known hazards The...

Page 5: ...hich 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 BS5440 1 1990 sub clauses 3 3 and 4 2 5 If the boiler is to ...

Page 6: ... Bracket Unscrew the side panel securing screw Slide the side panel forward and lift off casing Open the controls door Unscrew the front cover securing screws 5 4 1 2 3 660 5 5 125 Bottom Clearance Side Clearance Side Clearance Top Clearance Front Clearance All Dimensions in mm 275 15 410 50 Hinge forward pull bottom of cover forward and lift off 40 85 Gas Valve 15 F ront Injector Manifold Rc B S ...

Page 7: ...below The free area of each vent may be halved if the ventilation is provided directly from outside Free Area 323 cm If the boiler is installed in a cupboard or compartment with a door allow at least 15 mm clearance between the 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 400m...

Page 8: ...NT GROUND OR BALCONY LEVEL 300 H FROM A SURFACE FACING THE TERMINAL 600 I FACING TERMINALS 1 200 J FROM OPENING DOOR WINDOW IN CARPORT INTO DWELLING 1 200 K VERTICALLY FROM A TERMINAL ON THE SAME WALL 1 500 L HORIZONTALLY FROM A TERMINAL ON THE SAME WALL 300 N ABOVE ROOF LEVEL TO BASE OF TERMINAL 300 P FROM ADJACENT WALL TO FLUE 210 Q FROM INTERNAL CORNER TO FLUE 230 R BELOW EAVES OR BALCONY 600 S...

Page 9: ...g 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 calculate the volume of water in the sy...

Page 10: ...Installation Requirements Page 10 ...

Page 11: ...tion The resistance through the heat exchanger when operating with a water flow rate producing 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 system the resistance 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 w...

Page 12: ...Flue Kits Page 12 Installation instructions included as necessary with each kit ...

Page 13: ...Other Kits Page 13 Installation instructions included as necessary with each kit ...

Page 14: ...y cut the flue hole through the wall See fig 8 for Side Flue 7 Place the mounting template centrally over the hole ensure the template is level and mark out the two screw fixing hole positions 8 Remove the template and drill the two holes using a 7mm drill 9 Insert wall plugs and secure the mounting bracket to the wall using three No 12 x 2 woodscrews 10 Lift the boiler onto the mounting bracket s...

Page 15: ... the pilot hole and secure with self tapping screw 4 Wrap tape around the joint on the outer duct to seal the flue slide drip ring into a position to coincide with the air gap in the wall cavity wall 5 Slide the flue through the hole until it stops on the pin 6 The boiler is supplied with the flue elbow set to the rear For side outlet slacken the screws and turn the elbow to the required position ...

Page 16: ...nection 3 Take up excess slack in the cables between the terminal block and the cable clamp then tighten the cable clamp screws Ensure sufficient slack is available to the cable clamps to allow the control panel to hinge freely Check by opening the control panel If fitting the optional Potterton timer go to section 2 4 before performing steps 4 and 5 below 4 Secure the controls assembly to the cha...

Page 17: ... the gas supply is isolated Connect the gas supply using a suitable adaptor to the gas cock Important Do not solder the fitting whilst assembled to the gas cock 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 selected in accordance with BS 6891 so that an adequate gas supply to the boiler is provided Do not turn t...

Page 18: ...Installation Page 18 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 19: ...r adjustment must only be carried out by a suitably qualified personnel Potterton Myson Ltd offer this service on a chargeable basis Important When checking for gas soundness open all windows and doors in the room Extinguish all naked lights cigarettes pipes etc ...

Page 20: ...hat 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 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 lightin...

Page 21: ...for gas soundness 8 Stick the self adhesive arrow from the literature pack onto the data badge to indicate the appropriate burner setting pressure 9 Re fit the controls cover and secure with the screw previously removed Control Thermostat At its minimum and maximum settings the thermostat should control the water flow temperature at approximately 57 C 82 C Set the temperature control knob to O Sta...

Page 22: ...ce 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 debri...

Page 23: ...the boiler 8 If the injectors are removed use a new sealing washer when re fitting each 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 Refit baffle plate and ensure that any electrical connections are in plac...

Page 24: ...ires and connectors 4 3 2 Air Pressure Switch Gain General Access See 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 assemble in reverse order ensure that the Normally Closed N C ter...

Page 25: ...d side of the burner onto the support tab on the side insulation Hook the rear of the locating bracket 2 in place before locating the front 3 and re fitting the screw 4 3 5 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 4 3 Remove the two screws securing the side and rear insulation assembly to ...

Page 26: ...he burner See 4 3 4 4 Remove the two screws securing 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 i...

Page 27: ...l 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 assemble in reverse order SUP0076B Be careful when removing the fan not to damage...

Page 28: ...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 29: ...nscrew 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 excha...

Page 30: ...No 1 12 The control will continue to run the pump for several minutes after any firing of the boiler 13 The control will run the pump automatically for a few minutes every twenty four hours to maintain the free running of the pump 14 The standby position on the thermostat control knob will prevent the boiler firing but will permit operation of the pump for sequences 12 and 13 SUP0041B J5 J9 J6 J8 ...

Page 31: ...6 Wiring Diagram Page 31 ...

Page 32: ......

Page 33: ...e Air Pressure Switch Contacting CLOSED CIRCUIT Replace the Fan After 1 minute does RED LED FLASH GREEN LED come on continuously Apply Permanent Mains Supply Is the RED LED on only Is the RED LED still on Is the GREEN LED flashing Slowly 2Hz Turn Boiler Stat on to MAXIMUM Does RED LED extinguish Turn on EXTERNAL CALL for heat Are all the lights OFF Press RESET Button NO NO NO NO NO NO NO NO NO NO ...

Page 34: ...7 Fault Finding Guide Page 33 ...

Page 35: ... Replace Electrode First replace capacitor second replace the FAN Check Air Pressure Switch associated Tubes Were Sparks discharging elsewhere Rectify or replace the Electrode or Lead Were Sparks visible in viewing window whilst GREEN Light was Flashing Rapidly Is 200v dc present across GAS VALVE whilst GREEN Light is Flashing Rapidly Is Flame Visible during Rapid Flashing period of GREEN Light Bo...

Page 36: ......

Page 37: ...8 Short List of Spare Parts Page 34 SUP0083D L 365mm L 365mm L 462mm L 476mm ...

Page 38: ...4 864 Thermostat Knob 1 8238172 11 173 155 Pressure Switch Honeywell 1 8642227 12 Fan Assembly 100 1 409597 13 114 811 Fan Gasket 1 8238165 14 173 130 Overheat Thermostat 1 8404517 15 173 139 Injector Main Burner 100 2 8411028 16 337 862 Flue Scraper 1 907736 17 114 873 Front Panel Seal Type 1 1 8650691 17a 114 874 Front Panel Seal Type 2 2 8650692 17b 114 875 Front Panel Seal Type 3 8650693 18 11...

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