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Potterton Suprima 80 User Manual

Potterton Suprima 80
37 pages
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See inside cover for models covered by these instructions
Installation & Service Instructions
Suprima 30 - 80
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.
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Potterton Suprima 80 Specifications

General IconGeneral
ModelSuprima 80
ManufacturerPotterton
CategoryBoiler
Fuel TypeGas
Output80, 000 BTU/h
Efficiency78%
TypeConventional
MountingWall-mounted
Output (kW)23.4 kW
Central Heating Max Power23.4 kW

Summary

Introduction

Gas Safety Regulations Overview

Overview of Gas Safety (Installation and Use) Regulations 1994 and compliance.

Boiler Description

Description of Suprima boilers as automatically controlled, wall-mounted, balanced flue appliances.

Delivery and Kits Information

Information on boiler delivery packages and available kits.

Installation Requirements

Health and Safety Information

Information on hazardous substances and personal protective equipment for installers and service engineers.

Codes of Practice

Requirements for installation compliance with regulations and standards.

Gas Supply Requirements

Requirements for gas supply installation, including meter and pipe testing.

Electricity Supply Requirements

Electrical supply requirements, including fused switch and cable specifications.

Boiler Location Guidelines

Guidelines for selecting a suitable and safe location for boiler installation.

Air Supply Ventilation

Requirements for air supply ventilation in boiler installations, specifying vent areas.

Flue System Options

Details of horizontal, vertical, and vertex flue systems, including lengths and resistance.

Flue Terminal Location

Guidelines for positioning flue terminals to ensure safe discharge of combustion products.

System Design Considerations

System design requirements, including pump wiring, zone valves, and bypass circuits.

Expansion Vessel Sizing

Guidance on selecting and sizing expansion vessels for sealed systems.

Water Make-up Methods

Methods for replenishing water in the system, including vessel or mains top-up.

Mains Connection Restrictions

Restrictions on connecting to the mains water supply without authority approval.

Filling Point Requirements

Requirements for the system filling point, including stop valves and check valves.

Circulation Pump Selection

Guidance on selecting circulation pumps based on system resistance and boiler output.

Flue Kits

Concentric Vertical Flue Kit

Details and components of the concentric vertical flue kit.

Telescopic Horizontal Flue Kit

Components and options for the telescopic horizontal flue kit.

Vertex Flue System

Components and details for the Vertex flue system.

Twin Tube Vertical Flue Kit

Components for the twin tube vertical flue kit for different models.

1m Flue Extension Kit

Details of the 1m flue extension kit and its components.

Roof Flashing Kits

Description of flat and pitched roof flashing kits.

In-Line Bend and Elbow Kits

Components for 90° and 135° in-line bend and elbow kits.

Flue Kit Adaptors and Extensions

Details of adaptors, extensions, wall plates, and internal fitment kits.

Terminal Guard and Bend Adaptor

Details of the terminal guard and telescopic in-line bend adaptor.

System and Other Kits

Boiler Mounting Frames

Details and sales codes for boiler mounting frames.

Sealed System Module

Components and description of the sealed system module kit.

Mid Position Valve Kit

Details of the mid position valve kit.

Flue Turret Cover

Description and sales code for the flue turret cover.

Boiler Stand Off Kit

Components and sales code for the boiler stand off kit.

Programmer Kit

Details and components of the programmer kit.

Anti-theft Kit

Details and sales code for the anti-theft kit.

Installation

Unpack and Prepare Boiler

Instructions for unpacking the boiler, removing covers, and preparing for mounting.

Install the Flue

Steps for installing the flue system, including length calculations and types.

Flue Measurements

Diagrams and calculations for flue measurements based on wall thickness and configuration.

Connect Power Supply

Instructions for connecting the power supply to the boiler, including wiring details.

Frost Thermostat Installation

Information on fitting and connecting a frost thermostat.

Install Optional Programmer

Steps for installing the optional programmer unit.

Connect Gas Supply

Guidelines for connecting the gas supply pipework to the boiler.

Connect Water System

Instructions for connecting the system pipework to the boiler.

Commissioning

Commission the Boiler

Steps for commissioning the boiler, including flushing, filling, and initial checks.

LED Indicator Status

Explanation of LED indicators and their meanings during boiler operation and faults.

Boiler Operational Faults

Guidance on troubleshooting common boiler operational faults using LED indicators.

Final Adjustments

Procedures for final adjustments, including pressure checks and burner settings.

Control Thermostat Operation

Information on the control thermostat's function and settings.

Overheat Thermostat

Details on the overheat thermostat, its reset, and function.

Installer to User Instructions

Guidance for the installer on instructing the user on boiler operation and controls.

User Advice

Advice for the user on timer settings, frost precautions, and servicing.

Servicing and Component Replacement

Cleaning Boiler Components

Instructions for cleaning specific boiler components like the heat exchanger and burner.

General Access for Servicing

Procedures for gaining general access to boiler components for servicing.

Servicing the Boiler

Detailed steps for servicing the boiler, including fan, flue hood, and burner.

Component Replacement Overview

General warning and notes before replacing boiler components.

Electronic Control Board

Steps for gaining access to and replacing the electronic control board.

Air Pressure Switch

Steps for gaining access to and replacing the air pressure switch.

Electrode Replacement

Steps for gaining access to and replacing the electrode, including gap setting.

Burner Replacement

Steps for removing, transferring parts, and re-assembling the burner.

Injector Replacement

Steps for removing and replacing the injector, including using a new washer.

Combustion Chamber Insulation

Steps for accessing and replacing the combustion chamber insulation.

Gas Valve Replacement

Detailed steps for removing, replacing the gas valve, and refitting the manifold.

Fan and Flue Hood

Steps for disconnecting, removing, and re-assembling the fan and flue hood.

Temperature Sensor Replacement

Steps for disconnecting and replacing the temperature sensor.

Overheat Thermostat Replacement

Steps for disconnecting and replacing the overheat thermostat.

Heat Exchanger Replacement

Detailed steps for draining, removing, and replacing the heat exchanger.

Functional Wiring Diagram

Boiler Lighting Sequence

Step-by-step explanation of the boiler's ignition and lighting sequence.

Wiring Diagram

Fault Finding Guide

Initial Conditions and Checks

Pre-checks required before starting the fault finding process.

Short List of Spare Parts

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