Potterton Suprima 100 Installation and maintenance instructions

Installation & Service Instructions
Suprima 100
Wall Mounted Fan Assisted
Balanced Flue Gas Boilers
SUP0003B
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.

Contents - Page2
Technical Data ............................................................... 3
Introduction.................................................................... 4
1. Installation Requirements...................................... 4
1.1 Health & Safety Information............................... 4
1.2 Codes of Practice............................................... 4
1.3 Gas Supply......................................................... 5
1.4 Electricity Supply................................................ 5
1.5 Location of Boiler ............................................... 5
1.6 Air Supply........................................................... 7
1.7 Flue Systems ..................................................... 7
1.8 Flue Terminal Location....................................... 8
1.9 The System........................................................ 8
Flue Kits.................................................................... 12
Other Kits.................................................................. 13
2. Installation............................................................... 14
2.1 Unpack & Prepare the Boiler.............................. 14
2.2 Install the Flue.................................................... 15
2.3 Connect the Power Supply Cable...................... 16
2.4 Install the Optional Programmer........................ 17
2.5 Connect the Gas Supply.................................... 17
2.6 Connect the Water Supply................................. 18
3. Commissioning........................................................19
3.1 Commission the Boiler........................................20
3.2 Final Adjustments ...............................................21
3.3 Instruct the User..................................................21
3.4 Advise the User...................................................21
4. To 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 Exchanger.....................................29
5. Functional Wiring Diagram.....................................30
6. Wiring Diagrams......................................................31
7. Fault Finding ............................................................32
8. Short List of Spares.................................................34
The models covered by these instructions are:-
Suprima 100 - G.C. No.41 607 82
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.
Boiler
Code
Number
Bar
Code
Model
GC. No.
Data
Badge
Controls
Cover
SUP0085A
AHHV 611 0001
G. C. No. 41.607.82

Technical Data Page 3
Nominal Boiler Ratings
Boiler Output Input Burner Setting pressure Gas Rate Injector Size
Models kW Btu/h kW Btu/h mbar in wg m³/h ft³/h mm dia
100 28.72 98,000 35.9 122,500 13.6 5.54 3.42 120.9 3.2
Maximum Working Head 30.5 m (100 ft)
Minimum Working Head 150 mm (6 in)
Gas Supply Pressure 20 mbar
Gas Supply Connection Rc. ½ (½ in BSP Female)
Maximum Flow Temperature 82°C
Flow/Return Connections 22 mm Copper
Water Content 2.1 litres (0.46 gal)
Appliance Lift Weight 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 Gas Appliance Directive.
The Directive lays down requirements for the safety and efficiency of the appliance,
together with its design, construction, and use of materials.
It also requires the production process to be covered by an approved and monitored
system of quality assurance.

Introduction - Page 4
Gas Safety (Installation & Use) Regulations 1994
(As Amended).
This appliance must be installed and serviced by a
competent person, in accordance with the above regulations.
In the UK 'Corgi' Registered Installers (including the regions
of British Gas Plc) undertake to work to a safe and
satisfactory standard.
Failure to install appliances correctly could lead to
prosecution.
It is in your own interest, and that of safety, to ensure that
the regulations are complied with.
Suprima boilers are fully automatically controlled, wall
mounted, fan powered, balanced flue appliances using a
cast iron heat exchanger.
The boilers are designed for use on fully pumped open
vented or sealed water systems with an indirect hot water
cylinder.
THEY MUST NOT BE CONNECTED TO A DIRECT
CYLINDER.
The boilers are for use on Natural Gas (G20) only.
Samples of the Potterton Suprima gas boilers have been
examined by British Gas Plc, a United Kingdom Notified
Body. The range is certified to comply with the essential
requirements of the Gas Appliance Directive 90/396/EEC,
the Low Voltage Directive 72/23/EEC and shows compliance
with the Electro Magnetic Compatibility Directive
89/336/EEC and are therefore permitted to carry the CE
Mark.
Delivery & Kits Available
The unit is delivered in two packages (1) the boiler with
fittings and (2) the flue/terminal assembly. See page 12 for
flue options.
Various kits are available for the Suprima 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 following substances are also present.
Insulation and Seals
Material - Man Made Mineral Fibre.
Description - Boards, Ropes, Gaskets.
Known Hazards - Some people can suffer reddening and
itching of the skin. Fibre entry into the eye will cause
foreign body irritation which can cause severe irritation
to people wearing contact lenses. Irritation to respiratory
tract.
Precautions - Dust goggles will protect eyes. People with a
history of skin complaints may be particularly susceptible
to irritation. High dust levels are only likely to arise
following harsh abrasion.In general, normal handling
and use will not present high risk, follow good hygiene
practices, wash hands before, touching eyes, consuming
food, drinking or using the toilet.
First Aid - Medical attention must be sought following eye
contact or prolonged reddening of the skin.
1.2 Codes of Practice
The boiler must be installed in accordance with: The Gas
Safety (Installation and Use) Regulations 1994 (As
Amended) and the current issue of:-
The Building Regulations, Building Standards (Scotland)
Regulations, Local Building Regulations, Model and local
Water Undertaking Bye-laws, IEE Wiring Regulations and
Health & Safety Document No. 635 "The Electrician At Work
Regulations 1989".

Installation Requirements - Page 5
1.3 Gas Supply
The meter and supply pipes must be capable of delivering this quantity of gas in addition to the demand from any other
appliances in the house and must be governed at the meter.
The complete installation must be tested for gas soundness and purged as described in BS6891.
1.4 Electricity Supply
230V ~ 50Hz via a fused double pole switch with a contact separation of at least 3 mm in both poles adjacent to the boiler.
Power consumption is approximately 150W. There must be only one common isolator for the boiler and its control system
and it must provide complete electrical isolation.
Fuse the supply at 3 A. The minimum requirement for the power supply cable is that it should be a PVC sheathed cord at
least 0.75 mm² (24 x 0.2 mm) (code designation HO5 VV-F or HO5 VVH2-F) as specified in table 16 of BS6500:1984.
All wiring external to the boiler shall comply with the latest IEE Wiring Regulations, and any local regulations which apply.
WARNING: THIS APPLIANCE MUST BE EARTHED.
In the event of an electrical fault after installation of the boiler, preliminary electrical systems checks must be carried out i.e.
Earth Continuity, Short Circuit, Polarity and Resistance to Earth.
1.5 Location of Boiler
The boiler is not suitable for external installation unless it is suitably protected.
The boiler must be installed so that the flue terminal is exposed to the external air. It is important that the position of the
terminal allows the free passage 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
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 be installed in a timber framed building it should be fitted in accordance with the British Gas publication-
Part 19 - Building and Kitchen Work. If in doubt advice must be sought from Potterton Myson.
The boiler may be installed in any room, although particular attention is drawn to the requirements of the current IEE Wiring
Regulations and, in Scotland, the electrical provisions of the Building Standards applicable in Scotland with respect to the
installation of the boiler in a room containing a bath or shower.
Where a room-sealed appliance is installed in a room containing a bath or shower, any electrical switch or appliance control,
utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower.
Where the installation of the boiler will be in an unusual position, special procedures may be necessary and BS6798 and
BS5546 give detailed guidance on this aspect.
A cupboard or compartment used to enclose the boiler must be designed and constructed specifically for this purpose. An
existing cupboard or compartment may be used provided that it is modified for the purpose. Details of essential features of
cupboard/compartment design including airing cupboard installations are given in BS6798 and BS5546 and should be
complied with.
The boiler requires only the clearances shown on Page 6, after installation.

Installation Requirements - Page 6
SUP0070B
Side
View
Boiler Dimensions
Remove The Outer CaseBoiler Clearances
Flow
(22mm)Return
(22mm)
200 200
Side
Cover
Wall
Wall
Top of
Flue
Boiler
Chassis
34
122.5137.5
61
255
260 (To Wall)
315
400
485.5
600
105
53
33
29
60
Mounting
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
41
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
Front
Injector
Manifold
Rc ½"
½" B.S.P.
Female
Gas Cock
Gas
Valve
25
25
Front
View
Servicable
Clearance
610

Installation Requirements - Page 7
1.6 Air Supply
The air requirements must meet BS 5440 Part 2.
The room in which the boiler is installed does not require a purpose provided air vent.
If the boiler is installed in a cupboard or compartment, permanent air vents are required in the cupboard or compartment,
one at high level and one at low level, either direct to the outside air or to a room. Both high level and low level air vents
must communicate with the same room or must be on the same wall to outside air. Both the high level and low level vent
must each have a free area as stated below. The free area of each vent may be halved if the ventilation is provided directly
from outside.
Free Area - 323 cm²
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 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 (150mm/6in) are achieved by cutting with an
overlap of 20mm.
Under no circumstances should the total flue length exceed 680mm (no bends allowed).
Vertical
Vertical Concentric system.
Maximum actual length 1.4m, no bends allowed.

Installation Requirements - Page 8
1.8 Flue Terminal Location
If a horizontal flue is sited less than 2m above a balcony, above ground, or above a flat roof to which people have access, a
suitable terminal guard must be fitted. This serves two purposes, to protect the terminal against damage or interference and to
protect passers-by. A terminal guard is available (Sales Code: PTERMGUARDEF).
Note: Where a flue terminal is installed less than 1 metre from a plastic, or painted gutter, or 500mm from painted eaves, an
aluminium shield 1 metre long, should be fitted to the underside of the gutter or painted surface. A suitable wall plate should be
fitted to the painted wall surface of a mobile home.
IMPORTANT: It is absolutely ESSENTIAL, to ensure that products of combustion discharging from the terminal cannot re-enter the
building, or any other adjacent building, through ventilators, windows, doors, natural air infiltration, or forced ventilation/air
conditioning. If products of combustion are found to be re-entering any building, the appliance MUST be turned OFF
IMMEDIATELY.
K
G
D
F
J
A
A
B,C
B,C
C
E
FGGG
G
K
L L
K
K
FF FF
Flue
Terminals
P
R
Q
S
N
N
H,I
Below Carport
Vertical Flues
Q
A
N
Horizontal Flues
SUP0032B
POSITION MIN. DISTANCE mm
TO EDGE OF TERMINAL
HORIZONTAL FLUES
ADIRECTLY BELOW AN OPENABLE
WINDOW, AIR VENT, OR ANY OTHER
VENTILATION OPENING 300
BBELOW GUTTER, DRAIN/SOIL PIPE 25
CBELOW EAVES 25
DBELOW A BALCONY/CARPORT ROOF 25
EFROM VERTICAL DRAIN PIPES AND
SOIL PIPES 25
FFROM INTERNAL OR EXTERNAL CORNERS 100
GABOVE ADJACENT GROUND OR BALCONY
LEVEL 300
HFROM A SURFACE FACING THE TERMINAL 600
IFACING TERMINALS 1,200
JFROM OPENING (DOOR/WINDOW) IN
CARPORT INTO DWELLING 1,200
KVERTICALLY FROM A TERMINAL ON THE
SAME WALL 1,500
LHORIZONTALLY FROM A TERMINAL ON
THE SAME WALL 300
NABOVE ROOF LEVEL (TO BASE OF TERMINAL) 300
PFROM ADJACENT WALL TO FLUE 210
QFROM INTERNAL CORNER TO FLUE 230
RBELOW EAVES OR BALCONY 600
SFROM FACING TERMINAL 1,200
1.9 The System
The boiler must be used on Indirect Fully Pumped systems only,
which may be sealed or open vented.
The system should be designed so that the maximum static
head does not exceed 30.5m (100ft) and a minimum of 150mm
(6in).
On all systems the pump live connection should be wired to the
boiler terminal block, it will then be controlled by the pump over-
run. This will ensure that the pump will continue to run after
boiler shut down if the water temperature is high, thus
preventing nuisance operation of the overheat thermostat.
It is important that where electrically operated zone valves
are used the boiler is wired so it does not cycle when the
zone valves are closed. Also, systems fitted with controls
that close both hot water and central heating circuits while
the boiler is still hot, must be fitted with a by-pass circuit to
dissipate the residual heat from within the boiler.
If a three port valve is used as shown in Fig. 3 a by-pass is
not necessary since one circuit is always open.
Where a pair of two port valves are used, a by-pass is
necessary. The total length of the by-pass circuit taken from
the boiler connections should be greater than 4 metres of
22mm pipe. It should be fitted with a lockshield valve and
be adjusted to maintain a minimum flow through the boiler
of 4.5litres/min (1 gal/min).

Installation Requirements - Page 9
Systems fitted with controls which allow the boiler to operate
when both the hot water and central heating circuits are
closed i.e. mechanically operated thermostatic control
valves, must be fitted with a by-pass circuit of:-
1. A minimum length of bypass of 2m of 22mm dia. pipe.
2. Maintaining a minimum water flow rate through the
boiler of 9 litres/min (2 gal/min).
A suggested method of meeting these requirements by using
a bathroom radiator fitted with two lockshield valves is
shown in Fig. 3.
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
positioned on the heat exchanger.
Sealed Systems
Installation
The installation must comply with the requirements of BS
6798: 1987 and BS 5449: Pt 1. The British Gas publication
"British Gas Specification for Domestic Wet Central Heating
Systems" should also be consulted.
Pressure Relief Valve
A non-adjustable spring-loaded pressure relief valve, preset
to operate at 3 bar (45lbf/in²) shall be used. It must comply
with BS 6759: Pt 1. and include a manual testing device. It
shall be positioned in the flow pipe either horizontally or
vertically upwards and close to the boiler. No shut-off valves
are to be placed between the boiler and the safety valve.
The valve should be installed with a discharge pipe which
permits the safe discharge of steam and hot water such that
no hazard to persons or damage to electrical components is
caused.
Pressure Gauge
A pressure gauge incorporating a fill pressure indicator,
covering the range 0 - 4 bar (60 lbf/in²) shall be fitted to the
system. It should be connected to the system, preferably at
the same point as the expansion vessel. Its location should
be visible from the filling point.
Expansion Vessel
A diaphragm type expansion vessel to BS 4814: Pt 1. shall
be fitted close to the inlet side of the pump. The connecting
pipework should not 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 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: 2.1 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 Radiators: 2 litres per kW of system
output
Hot Water Cylinder: 2 litres
If the system is extended, the expansion vessel volume may
have to be increased unless provision has been made for
extension. Where a vessel of the calculated size is not
available, the next available larger size should be used. The
boiler flow temperature is controlled at approximately 82°C.
The vessel size can now be determined from the information
in Table 1 where V = System volume in litres.
Table 1.
Cylinder
The hot water cylinder must be an indirect coil type or a
direct cylinder fitted with an immersion calorifier suitable for
operating at a gauge pressure of 0.3 bar (5 lbf/in²) in excess
of safety valve setting. Single feed indirect cylinders are not
suitable for sealed systems.
Method of Make-up
Provision shall be made for replacing water loss from the
system either:-
i) from a make-up vessel or tank mounted in a
position higher than the top point of the system, and
connected through a non-return valve to the system
on the return side of the hot water cylinder or the
return side of all heat emitters.
or
ii) where access to a make-up vessel would be difficult
by using the mains top up method or a remote
automatic pressurisation and make-up unit as
shown in Figs. 5 & 6.
Mains Connection
There shall be no connection to the mains water supply or to
the water storage tank which supplies domestic hot water
even though a non-return valve, without the approval of the
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 (approved by the National Water Council) to be
fitted in this order from the system mains, see Fig. 5.

Installation Requirements - Page 10

Installation Requirements Page 11
Fig. 5 Fig. 6
Double
Check Valve
Heating
SystemHeating System
Stop
Valve Stop Valve
Mains Water Supply
(Service Pipe)
Stop
Valve
Method 1Method 2
Mains Topping-up MethodCistern Filling Method
NOTE: This method of filling
a sealed system may only be
used if acceptable to the Local
Water Undertaking
NOTE: Cistern to be supplied through
a temporary connection from a service
pipe or cold water distribution pipe
Cistern
Pressure Pump Reducing
Valve (If Required)
Mains
Water
Supply
Overflow
Temporary Connection
(Flexible Hose With Union)
SUP0009B
Circulation Pump Selection
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
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.
SUP0072A
Pressure Drop (metres)
Flow Rate (litres/min.)
0
0
1
2
3
4
5
20406080
Flow rate for
11° C diff.
@36 kw output.
Flow rate for
20° C diff.
@17.8 kw
output.
Resistance
Hydraulic Resistance
100 Model

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

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

2. Installation - Page 14
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 boiler.
2. Do not discard any packaging until all the
items are accounted for.
3. Open the controls cover, remove the
securing screw and washer, pull off the
controls cover and put safely aside.
4. Remove two screws and washers, remove
the white front case and put safely aside.
5. Place the mounting template in the
proposed boiler position ensuring that it is
level. Minimum clearances are accounted
for on the template.
6. Mark the flue hole, remove the template
and carefully 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,
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 the boiler is
mounted on the wall. This screw can be
replaced by an anti-theft kit see note
below.
Note: There is provision for an anti-theft
securing point (sales code: SUPKITP) which
may be used if required.

Installation - Page 15
2.2 Install the Flue
Maximum flue lengths are as follows:
100 Model - 680mm
Note: For flue lengths less than the minimum
telescopic length, the tubes can be cut to suit.
Ensure that the same length is removed from the
inner and outer tubes to maintain a 20mm
overlap (minimum).
These instructions are for rear and side flue
applications.
Rear Flue
1. Measure the wall thickness and add 66mm
(or 106mm for installations using the System
Boiler or Stand Off Kits).
Side Flue
1. Determine the X dimension (wall thickness +
distance to boiler centreline).
For both Rear & Side Flues
2. Extend the telescopic flue to the required
length, minimum 20mm overlap.
3. Drill through 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 and re-tighten screws. Ensure that
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 around the flue, both
outside and inside.

Installation - Page 16
2.3 Connect the Power Supply Cable
1. Cable clamping is provided on the front of the controls
panel. Feed the cables up and over the back of the
chassis, through the clamp and into the terminal
connection. Connect the wires, brown to L and blue to N
and green/yellow to earth .( ).
Note: When connecting the power supply cable, ensure
that the 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. 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 chassis using the
screw previously removed.
5. Carry out preliminary electrical system checks i.e. Earth
Continuity, Short Circuit, Polarity and Resistance to
Earth.
Frost Thermostat:
If a Frost Thermostat is to be fitted, the connections
should be made in the wiring external to the boiler.
The Frost Thermostat should be connected between the
Permanent Live & Switch Live in the supply cable to the
boiler.
Do not switch on the electricity supply at this stage.

Installation - Page 17
2.4 Install the Optional
Programmer
1. Carefully remove the blanking panel from
the facia and locate the programmer into
the cut out.
2. Remove the two plastic sleeves and
connect the programmers electrical plug
onto position J4 on the circuit board.
3. Connect the 3 way terminal block to the
metal work immediately below the
programmer using the two screws
provided.
2.5 Connect the Gas Supply
Ensure that 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 the gas supply on at this stage.
J5
J6
Programmer
Facia
Terminal Block
(3 way)
Orange
Violet
Yellow
Circuit
Board
J9
SUP0026A
Blue
Brown
J4
Connector
(2 way)
J4
Remove the two
plastic sleeves
Terminal
Block
Securing
Clips
Facia

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.

3. Commissioning - Page 19
Important
The Commissioning and boiler 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.

Commissioning - Page 20
3.1 Commission the Boiler
Open Vented Systems - Remove the pump and flush
the system thoroughly with cold water. Re-fit the pump.
Fill and vent the system then check for leaks.
Sealed Systems - Note: The system can be filled using
a sealed system filler pump with a break tank or by any
other method approved by the Local Water Authority.
Remove the pump and flush the system thoroughly with
cold water. Re-fit the pump. Fill and vent the system
until the pressure gauge registers 1.5 bar (21.5 lbf/in²)
and check for leaks. Raise the pressure until the safety
valve lifts, this should occur within ± 0.3 bar of the
preset lift pressure of 3 bar. Release water to attain the
correct cold fill pressure.
All Systems
Warning: Before lighting the boiler, ensure that the
outer white case has been correctly fitted and that
the sealing strip fitted to the outer white case is
forming a tight seal with the main boiler chassis.
The controls cover is left off at this stage.
Preliminary electrical system checks. These checks
must be carried out before attempting to light the boiler.
They are:- Earth Continuity, Short Circuit, Polarity &
Resistance to Earth.
1) The whole of the gas installation must be checked
for soundness and purged in accordance with BS
6891.
2) Set the boiler temperature control knob to 'O'
Standby.
3) Turn the boiler gas service cock to the 'On' position
and that the main gas supply is turned 'On'.
4) Make sure that the system is full of water and that
the pump and radiator isolating valves are open.
Vent air from the system.
5) Ensure that the main electricity supply is 'On'.
6) Check that the time control, if fitted, 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) 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 burner flame has established and the
burner lights the lower Green LED on the user control
panel will be on continuously.
LED Indicators
Status Green LED Red LED
Mains ON Only OFF ON
Ext. Call for Heat
(Boiler set to STNDBY
Temp. Control set to 'O' Off)
FLASHING
2 Per Sec. ON
Ext. Call for Heat
(STNDBY switch to ON,
Temp. Control set to Max.)
FLASHING
2 Per Sec. OFF
Ignition
(i.e. Gas and Sparks ON) FLASHING
16 Per Sec. OFF
Boiler Temperature
Control Satisfied FLASHING 2 Per Sec. ON
FLAME Detected ON OFF
8) With the main burner running, check for gas
soundness using leak detection fluid.
9) Allow the system to reach maximum working
temperature and examine for water leaks. Set the
temperature control to 'Standby' and drain the
system whilst still hot.
Note: Should the boiler fail to operate correctly refer to
the Fault Finding Guide and the boiler wiring diagram
for further information.
10) Re-fill and vent the system making a final check for
leaks.
On sealed systems adjust to the correct cold fill
pressure. Set the pressure gauge pointer to the system
design pressure.
If a by-pass circuit is fitted the by-pass valve should be
adjusted with the boiler operating under minimum load
conditions to maintain sufficient water flow through the
boiler to ensure that the overheat thermostat does not
operate under normal conditions.