Potterton Suprima 30 User manual

To be used with Suprima 30 - 60 models ONLY
Installation Instructions
Suprima System Boilers
with Mid Position Valve Kit Option
Wall Mounted Fan Flued Gas Boilers

2Sealed System Boiler Publication No. 559931
Pack Contents - Page 2
Boiler Mounting Frames
Sales Code: 1SUPKITL
and
Sales Code: 2SUPKITL
Optional Mid Position Valve Kit
Sales Code: SUPKITN
Mid Position
Valve
Mounting Frame
(Isolating Valves Pre-fitted)
Mounting Frame
Fixings & Grommet
Junction
Box
Support
Bracket
Wiring
Diagrams
Supplied with Sealed System Module
'O' Ring
'O' Ring
SUP0050B
Pipe to fitting
(Hot Water)
Pipe to fitting
(C. Heating)
Template (with fitting the frame included)
Olive
Nut
Gas
Cap
Frame
Locknut
Gas
Adaptor
...Standard for use without
Mid Position Valve
...Standard for use with
Mid Position Valve
15mm Pipe
(NOT Supplied)
Isolating Valve
Fittings For Frame
No.238037 (Standard)
Isolating Valve
Fittings For Frame
No.238038 (MPV)
Fig. 2

Sealed System Boiler Publication No. 559931 3
Pack Contents - Page 3
Instructions
Olive
Olive
Gas
Pipe
Cable
Clamp
SUP0069C
Sealed System Module
Sales Code: 1SUPKITK
Automatic Bleed Valve
Return
Pipe
Pump
Bulkhead
Connector
Expansion Vessel/
Pump
Carrier
Assembly
System Casing
Pressure
Gauge
Pressure
Relief Valve
P.R.V.
Discharge
Pipe
Expansion Vessel
Flexible
Hose
Pump
Manual Bleed
Valve
Flow Pipe
Extension
(Standard)
Flow
Pipe
Boiler
Mounting
Bracket
Boiler
Securing
Screw
Expansion
Vessel
Adaptor
Return Tail
Pipe Assembly
Olive
Nut
(22mm)
Nut
(15mm)
Nut
(15mm)
Fig. 3

4Sealed System Boiler Publication No. 559931
Boiler Mounting Frame and Connections - Page 4
Flue Tube
Hole
ø102mm
61mm
410mm Minimum Clearance
1,210mm Minimum Clearance
840mm Height of Mounting Frame Slots
860mm Height of Mounting Frame
Minimum
Clearance
100mm
120mm
Isolating Valve
22mm
Return
Lock the
Isolating valves
to the frame
Locknut
Frame
Flow
C. Heating
Isolating valves are pre-fitted to mounting frame
Isolating
Valves
(MPV)
22mm
Hole for
Gas Adaptor
Flow
Hot Water
Isolating Valve
22mm Flow
SUP0051B
Hole for Safety
Valve Pipe
Positions for
Isolating Valves
(Standard) Positions for
Isolating Valves
(MPV)
Mark ,drill and
plug the four
frame mounting
slots as shown
(use a 7mm drill)
Frame
Mounting
Slots
Frame
Template
Olive
Nut
Connect the gas supply.
(Use a Gas Cap if the boiler
is to be fitted at a later date).
Gas Cap
Frame
15mm Pipe
(NOT Supplied)
Locknut
Gas
Adaptor
Grommet
Fig. 4
Install the Boiler Mounting Frame:
1. After unpacking the mounting frame decide
position of flue and mount the frame on the
wall. Use the template provided in the pack
which automatically allows for clearances etc.
2. Cut the flue hole through the wall. If the boiler
is not being installed immediately, the hole
should be temporarily blocked.
3. Using the hole as a datum, align the template
and mark off the wall frame fixing position.
Drill and plug the 4 holes.
4. Mount the frame onto the wall. Before finally
tightening the screws, ensure that the frame is
centrally positioned relative to the centre line of
the flue.
Connections:
Read both Bottom and Top connections before
making a decision on the pipework layout.
Bottom Connection
The boiler mounting frame allows the system
pipework to be connected and the system filled
with water, with gas piped to the frame.
1. Connect the flow and return pipes to the
isolating valves at the base of the wall frame
(22mm compression, In Eire use special ¾”
copper olives).
2. Isolate the gas supply at the meter. Fit the gas
supply pipe to the bulk head connector on the
base of the mounting frame using the nut and
olive supplied - See Fig. 4.
3. Ensuring that the isolating cocks are closed,
the system can be filled with water. If a
proprietary filling loop is used, a temporary
pressure gauge should be used. Do not
exceed 1 Bar fill pressure. Check the system
for leaks.
Note: The system should be filled at a point
convenient to a mains supply using one of the
methods described in the boiler instructions under
'Sealed Systems'.
Top Connection
This system can be used with top connections
provided the following points are observed.
a. The wall mounting frame, sales code
1SUPKITL (standard, without mid position
valve) is ONLY to be used.
b. That the boiler is installed at the same time as
the sealed system (NO pre-plumbing
facility).
c. The flow & flow pipe extension supplied with
the sealed system module is NOT to be used
together with one air vent.
d. The additional pipework is to be in
22mm dia. copper tube (not supplied),
see fig.5 for pipework layout.

Sealed System Boiler Publication No. 559931 5
Boiler Mounting Frame and Connections - Page 5
Mounting Frame
(without Mid
Position Valve)
Remove
Isolating
Valve from
Mounting Frame
Connect to
Return
Isolating
Valve
Run Return
Pipe from
Heating
Hot Water
Circuits
through
mounting
frame
(NOT
Supplied)
1
2
6
5
4
Flow
Pipe
Flow Pipe
Extension
Return
Pipe
Return Pipe
Connect Flow Pipe to boiler
Fit the Isolating Valve
removed from the
Mounting Frame
Follow the instructions
in this booklet to fit
the rest of the system module
(minus flow pipe & flow pipe extension)
Gas
Pipe
Boiler Pack
(30-60 Models Only)
SUP095A
Vessel/Pump
Carrier Assembly
Isolating
valve
(22mm)
ClosedOpen
System
Pipework
Connecting
Through
The Top
Fit
Automatic
Bleed Valve
Use the
existing hole
in frame
for pipework
3
1.0
0.5
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
00 5 10
Flow Rate (Litres/Min.)
Available Pump Head (Metres)
1520253035
Sealed
System
Pump
Head
Chart
Pump
Working
Range
Pump
Speed
1
Pump
Speed
3
Pump
Speed
2
Fig. 5

6Sealed System Boiler Publication No. 559931
The Sealed System Module - Page 6
SUP0057C
Mounting
Frame
Grommet
Vessel
Carrier
Securing
Screws
(2 off)
Vessel/ Pump
Carrier Assembly
Frame
Olive
Nut
Securing Screws
(4 off)
P.R.V.
Discharge
Pipe
Pressure
Relief
Valve
Olive
Nut
Mid Position
Valve
'O' Ring
'O' Ring
Flow Pipe
(C. Heating)
Securing Screws
(4 -off)
Flow Pipe
(Hot Water)
Nut
Frame
Flow
Pipe
Olive
Isolating valve
(22mm)
ClosedOpen
Drain Point
Nut
Frame
Connect
Flow Pipe
Extension
Olive
Drain
Point
Connect
Return
Tail Pipe To
Isolating Valve
Hole For
P.R.V. Pipe
Standard
Mid
Position
Valve
Fig. 6
This sub-assembly provides a support frame for
the expansion vessel, pressure relief valve,
pressure gauge, pump and inter-connecting pipes
and fittings. These components are pre-
assembled and includes the cable for the pump
feed, the flow, return and gas pipes with fittings
are included in this pack.
Fit the Module Assembly
1. Unpack the system module.
Offer the Vessel/pump Carrier Assembly up to
the Mounting Frame - See Fig. 6.
2. Fit the nut and olive to return pipe tail and
connect into the isolating valve.
3. Secure the Vessel/pump Carrier Assembly to
the Mounting Frame using the four screws
provided in the pack.
4. Unscrew the 2 Expansion Vessel Carrier
securing screws and swing down the Vessel
Carrier so that the interior pipework is more
accessible.
5. Tighten the tube nut on the top of the return
isolator valve.
6. Fit the Pressure Relief Valve Discharge Pipe
as shown opposite in Fig. 6.
Install the Flow Pipe Extension -
Standard
If the Mid Position Valve Kit Option is not being
used:-
1. Place the nut and olive over the tail end of the
Flow Pipe Extension.
2. Connect the extension to the Isolating Valve
and leave the connection loose.
Install the Mid Position Valve
(M.P.V.) Kit Option
1. Secure the M.P.V. outlet pipes to valve
(Flange connections), ensure that the ‘O’
rings are in position before inserting into the
valve.
2. Tighten the two screws in each flange
ensuring that the connection is sealed.
3. Fit the two nuts and olives, slide both outlet
tails into their respective isolating valve - See
Fig. 4. Tighten both nuts.

Sealed System Boiler Publication No. 559931 7
The Sealed System Module - Page 7
Flow and Return Pipes
The flow and return pipes can now be placed
into the Mounting Frame in the position
indicated in Fig. 7. The flow pipe must be on
the left-hand side. Do not attempt to fit these
pipes at this stage, hang both pipes on top
frame making sure they cannot be damaged
when the boiler is mounted to the frame.
Connect the Gas Pipe to the Frame
1. Isolate the gas supply at the meter.
2. Remove the cap from the bulkhead connector
- if fitted.
3. Loosely connect the gas pipe to the bulkhead
fitting using the nut and olive supplied.
Ensure that the pipe faces forward and is
through the notch in the frame. See Fig. 7.
Prepare the Boiler Before Mounting
to the Frame
Unpack the boiler and remove the side cover
and outer casing (See Installation Instructions
- Page 6). Then prepare the boiler as follows:
1. Remove the boiler alignment screws (two)
from the bottom rear of the boiler case.
2. Fit the Boiler Mounting Bracket, which is in
the system module, to the rear of the boiler.
Use the boiler alignment screw holes and the
two screws provided.
The Boiler Mounting Bracket must be
positioned so that the lug for the fixing hole is
at the bottom pointing outwards from the
back of the boiler, See Fig. 7.
3. Fit the adaptor (taper end) to the gas valve
fitting. See Fig. 6. Use a sealing compound
on the threads.
4. Slide the nut and olive onto the outlet and
return pipes.
Fit the Boiler to the Frame
1. The boiler can now be put into place by lifting
onto the two hooks provided at the top of the
Mounting Frame.
2. Secure the boiler to the Frame by using one
screw through the hole in the lug of the Boiler
Mounting Bracket into the screwed bush in
the Frame.
3. Fit the two locking clips supplied with the
boiler.
4. Fit the flue; follow the instructions in the
Installation Instructions under Section 2.2
Install the Flue.
SUP0055B
Gas
Pipe
Frame
Securing
point for
boiler
Boiler
Securing
Clip
Frame
Boiler
Boiler Mounting
Bracket
Securing Screw
Secure Boiler
Mounting
Bracket to
boiler
(2 countersunk
screws)
Fit flue into wall
then attaching the
boiler mounting
bracket to the boiler.
Lift boiler onto the
frame and connect flue.
(See Flue Instructions)
Back
of
boiler
Flow
Pipe
Return
Pipe
Hook Flow & Return Pipes
inside frame so they
cannot be damaged
when the boiler is fitted
Remove the two
boiler alignment
screws from
behind the boiler
Boiler
Mounting
BracketBoiler
Securing
Screw
Gas Valve
Fitting
Olive
Olive
Nut
15mm
Nut
15mm
Adaptor
(Taper to
Gas Fitting)
Olive
Nut
Use sealer
on the
threads
Fig. 7

8Sealed System Boiler Publication No. 559931
The Sealed System Module - Page 8
Mid Position
Valve
'O' Ring
'O' Ring
Flow Pipe
Flow Pipe
Connect The
Top Of
Flow Pipe
Extension
SUP0058B
Flow Pipe
Securing Screws
Flow Pipe
Securing
Screws
Fit
Automatic
Bleed Valve
Fit Manual Bleed Valve
Connect Flow
Pipe to boiler
Flow Pipe
(With Nut
& Olive)
Return Pipe
(With Nut & Olive)
Frame
Connect
Return
Pipe
Pump
Connection
Olive
Nut
This Cap
MUST
be LOOSE
Example of
Discharge
Pipe
Mains
Terminal
Block
N
N
Pump
Mains
L LSwLE E
This Appliance must be Earthed
Cable
Clamp
Supplied
(To secure
the pump
cable in
position)
Mains
Cable
Clamp
Control
Panel
Connect Return
Pipe to boiler
Fig. 8
Connect the Gas Pipe to the Boiler
1. Connect the gas pipe to the gas valve adaptor
using the nut and olive supplied. Tighten the nuts
on the gas valve and bulkhead adaptors, turn ON
the gas at the meter and test for gas soundness.
Connect the Flow and Return Pipes
1. Slide the flow pipe onto the boiler outlet
connection and engage the bottom end of the
tube onto the flow pipe extension (flanged fitting)
ensuring that the ‘O’ ring seal is in place or to the
flanged inlet on the M.P.V.
2. Tighten both connections and fit the Automatic
Bleed Valve (from the system module) to the
screwed connection. See Fig.8.
3. Slide the return pipe onto the boiler inlet
connection and engage the bottom end of the
tube into the fitting on the pump outlet.
(Compression fitting).
4. Tighten both connections and fit the Manual
Bleed Valve (from system module) to the
screwed connection. See Fig.8.
Pressure Relief Valves
The pressure relief valve on this module is pre-
set at 3 bar.
Install a pressure relief valve discharge pipe to
the valve, not less than 15 mm diameter and
connect to the tail pipe using a 15mm
compression fitting. The pipe run should be as
short as possible, run continuously downwards
and discharge to the outside of the building,
where possible over a drain.
The pipe end should be directed towards the
wall. The discharge point must be such that it will
not be hazardous to occupants or cause damage
to external electrical components or wiring.
IT MUST NOT DISCHARGE ABOVE AN
ENTRANCE, OR WINDOW, OR ANY TYPE OF
PUBLIC ACCESS. THE INSTALLER MUST
CONSIDER THAT THE OVERFLOW COULD
DISCHARGE BOILING WATER.
Venting the Boiler
The system can now be filled by connecting the filling
loop or opening the isolating valves. Pressurise and
top up to 1 Bar. Check for leaks. The pump must be
properly vented, it should NOT be run dry (this may
cause damage to the bearings).
Disconnect the filling loop.

Sealed System Boiler Publication No. 559931 9
The Sealed System Module - Page 9
Commissioning
Turn on the gas at the meter and test the installation
for soundness.
Follow the Boiler Installation Instructions Section 3
“Commissioning” (page 21) to complete the
installation of the system.
Re-fit the boiler casing, side casing and system
casing.
Wiring
For cable sizes see Section 1.4 'Electricity Supply' in
the instructions supplied with the boiler. Power
Consumption: Boiler - 150W M.P.V. - 5W Pump -
112W.
Wiring the Boiler
1. The pump can now be wired directly to the main
boiler terminal block, wire to be routed through
the cable clip and cable clamp provided.
Wiring Installation Without M.P.V.
1. The mains cable should enter the mounting frame
through the grommeted hole and run up the right
hand side of the Frame to the main boiler terminal
block. The instructions given in the Installation
Instructions under Section 2.3 (Page18) 'Connect
the Power Supply Cable' should be followed.
Fit the Junction Box (M.P.V. Only)
1. Fit the Junction Box and Support Bracket behind
the left hand Frame Member. See Fig. 9.
Note: For Terminal Connections refer to the Wiring
Diagrams, see Figs. 10, 11 & 12. All wires must be
clamped.
2. Run Mains Cable into the junction box.
3. The lead from the M.P.V. is also wired into the
same junction box.
4. Wire from the boiler mains input terminal back to
the boiler terminal in the junction box. The
instructions given in the Installation Instructions
under Section 2.3 (Page 18). 'Connect the Power
Supply Cable' should be followed.
5. The external controls can be fed into the junction
box and connect to room and cylinder stat
terminal in accordance with the instructions
provided with the respective control.
6. Carry out a preliminary electrical system check,
i.e., earth continuity, short circuit, polarity and
resistance to earth.
7. Refit cover over junction box.
SUP0059B
Terminal
Connector
(10 way)
Frame
Junction Box
Support Bracket
(Fitted behind Frame)
Junction
Box
Junction Box
Bracket
Securing
Screws
Junction Box
Securing Screws
Cable
Clamps
Install the bottom
cover by sliding
the top tabs into
the frame
Fit Side Cover and
Boiler Casing
Push to two bottom
securing pegs
into the frame
E
N
L
1
7
2
8
3
9
4
10
5 6
Securing
Screws
Junction Box
Cover
DANGER 230V
Fig 9

10 Sealed System Boiler Publication No. 559931
Wiring Diagrams - Page 10
SUP0060C
Potterton Electronic Controls
7
8
3
9
4
10
5 ENL
1 72 83 94
10
5 6
LN
Pump
Mid Position Valve
MSV 322 or 328
Mains
Cable
Frost
Stat
Junction
Box
External
Programmer
Cylinder
Thermostat
PTT2
Room
Thermostat
PRT2
Remove
Pump Cover
to check wiring
Key Colours:
br = Brown
o = Orange
b = Blue
gr = Grey
g/y = Green /Yellow
w = White
HW off
HW on
N
CH on
TL
TL
E
C
Com
L
L
N
H
N
Power Consumption:
150W - Boiler (approx)
5W - M.P.V. (approx)
112W - Pump (maximum)H
v
y
Optional
Programmer
PumpMains
This Appliance must be Earthed
Programmer
Wiring
Terminal
Connector (7 way)
Suprima Boiler
Optional
Programmer
Connector
(3 way)
NN L LE ESwL
CH
out
DHW
on
DHW
off
out
Fig. 10

Sealed System Boiler Publication No. 559931 11
Wiring Diagrams - Page 11
7
8
3
9
4
10
5 ENL
1 72 83 94
10
5 6
v
y
Optional
Programmer
PumpMains
This Appliance must be Earthed
Programmer
Wiring
Terminal
Connector (7 way)
Suprima Boiler
Optional
Programmer
Connector
(3 way)
N
N
LLEESwL
CH
out
DHW
on
DHW
off
out
SUP0062B
Potterton Mechanical Controls
LN
Pump
Mid Position Valve
MSV 322 or 328
Mains
Cable
Junction
Box
External
Programmer
Cylinder
Thermostat
PTT2
Room
Thermostat
PRT2
Remove
Pump Cover
to check wiring
HW off
HW on
N
CH on
TL
TL
E
C
Com
L
L
N
H
N H
Key Colours:
br = Brown
o = Orange
b = Blue
gr = Grey
g/y = Green /Yellow
Power Consumption:
150W - Boiler (approx)
5W - M.P.V. (approx)
112W - Pump (maximum)
Frost
Stat
Fig. 11

12 Sealed System Boiler Publication No. 559931
Wiring Diagrams - Page 12
7
8
3
9
4
10
5 ENL
1 72 83 94
10
5 6
SUP0063D
v
y
Optional
Programmer
PumpMains
This Appliance must be Earthed
Programmer
Wiring
Terminal
Connector (7 way)
Suprima Boiler
Typical Controls By Others
Optional
Programmer
Connector
(3 way)
LN
Pump
Mid Position
Valve
Mains
Cable
Junction
Box
External
Programmer
Cylinder
Thermostat
Room
Thermostat
Remove
Pump Cover
to check wiring
HW off
HW on
E
CH on
E
Satisfied
Common
Call
L
Common
N
Call
NE
N
N
LLEESwL
CH
out
DHW
on
DHW
off
out
Key Colours:
br = Brown
o = Orange
b = Blue
gr = Grey
g/y = Green /Yellow
w = White
NOTE: Colours shown for M.P.V.
are typicalof most motorised valves
Power Consumption:
150W - Boiler (approx)
5W - M.P.V. (approx)
112W - Pump (maximum)
Frost
Stat

Sealed System Boiler Publication No. 559931 13
Replacement of Parts - Page 13
Isolate the Boiler
1. Isolate the boiler from the electricity supply.
2. Close the Isolating Valves so the rest of the
system does not drain down.
Important: Release the system pressure by
turning the Pressure Relief Valve anti-clockwise.
3. Drain the system through the Drain Points
provided, the gas supply need not be isolated.
Vessel/ Pump Carrier Assembly
Note: How to replace the Pump, Pressure Relief
Valve, Expansion Vessel Flexible Hose and
Pressure Gauge are all shown in Fig.13.
Mid Position Valve
Note: If the Motor is not working this can be
replaced without disconnecting the water
system by:
1. Unscrew the Motor (Head) from the plate (2
screws) and disconnect.
2. Disconnect the wiring from the Junction Box
To replace the M.P.V. complete, follow stages
above and see Pages 6& 8for more details.
Isolating Valves
The complete system will have to be drained
down, see Pages 4& 6 for more details.
Vessel/
Pump
Carrier
Assembly
Pump Nut
Pump
Washer
Pump
Pump Bulkhead
Pump Bulkhead
Connector
Pump
Bulkhead
Connector
in position
Pump
Bulkhead
Locknut
Pump
Bulkhead
Return
Pipe
Nut
Olive
Mounting
Frame
Nut
Frame
Return Pipe
Extension Assembly
Olive
Drain Point
Isolating
valve
(22mm)
ClosedOpen
P.R.V.
Discharge Pipe
Pressure
Relief Valve
Olive
SUP0053B
Nut
Expansion Vessel
Flexible Hose
Vessel/Pump
Carrier Assembly
Pressure Gauge
(Minimum
Pressure
0.5 Bar)
POTTERTON
bar
13
4
2
0
Nut
Olive
Important
Turn Pressure Relief
Valve anti-clockwise
before draining down
the system
Pressure
Relief Valve
Fig. 13

14 Sealed System Boiler Publication No. 559931
Replacement of Parts - Page 14
SUP0054B
Fit Automatic
Bleed Valve
Fit Manual Bleed
Valve
Return Pipe
Flow Pipe
Expansion
Vessel Bleed
M.P.V. Version
Shown
Expansion
Vessel
Flexible Hose
Place the
Expansion
Vessel in
position
and connect
the Flexible
Hose
This Cap
MUST
be LOOSE
Expansion Vessel
1. Disconnect the flexible hose from the Vessel.
2. Lift the Expansion Vessel Out of its Carrier and
replace with a new one.
System Bleed Valves
1. Unscrew the Automatic Bleed Valve from the
top of the flow pipe.
Important: The cap MUST be left loose.
2. Unscrew the Manual Bleed Valve from the top
of the return pipe.
Venting the Boiler
The system can now be filled by opening the
isolating valves. Top up the system by connecting
the filling loop and pressurising to 1 Bar. Check for
leaks.
The pump must be properly vented, it should NOT
be run dry (this may cause damage to the
bearings).
Re-fit the boiler casing, side casing and system
casing. Check the boiler is working properly, see
installation instructions for more details.

Sealed System Boiler Publication No. 559931 15
Short List Of Spares - Page 15
SUP0061A
1
2
3
4
13
14
12
7
11
8
9
10
5
6
15
Fig. 15
Drg.
Ref G.C. No. Description No. Off. Makers Part No.
1 114988 Pump 1 411154
2 386562 Washer (Included with pump) 2404C587
3 114984 Pump Bulkhead Connector 2 238426
4 114985 Pump Nut 2 625993
5 289889 Expansion Vessel Flexible Hose 1 430043
6 173158 Expansion Tank 1 430171
7 379831 Pressure Relief Valve 1 430044
8 114744 Mid Position valve (Complete) 1 430135
9 114987 Replacement Head 1 930115
10 338233 ‘O’ Ring 3 401645
11 114977 Isolator Valve 3 430152
12 173161 Pressure Gauge 1 430101
13 173159 Automatic Bleed Valve 1 430054
14 173160 Manual Bleed Valve 1 430070
15 114986 Gas Connection Adaptor 1 625902