Potterton Suprima 30L Installation and maintenance instructions

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SUP0003A
AbouttheBoiler See inside cover for models covered by these instructions.
This is a Wall Mounted Fan Assisted Balanced Flue Gas Boiler.
This boiler is for use with Natural Gas (G20) only at 20mbar and for use in GB & IE.
AboutSafety TheGasSafety(InstallationandUse)Regulations1998.
‘‘Inyourowninterest,andthatofsafety,itislawthatallgasappliancesareinstalledbycompetent
persons, in accordance with the above regulations. Failure to install appliances correctly could
leadtoprosecution.’’
Installation must be in accordance with the Installation & Service Instructions and the rules in
force.
LeavetheseinstructionsandtheBenchmarkLogBookwiththeuserforuseonfuturecalls.
Installation & Service Instructions Suprima
30L - 100L
TM
The code of practice for the installation,
commissioning & servicing of central heating systems

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Publication No. 5102696
2
Contents
Contents
TechnicalData........................................................3
Introduction..................................................................4
1. InstallationRequirements................................4
1.1 Health&SafetyInformation...............................4
1.2 CodesofPractice.............................................4
1.3 Gas Supply.....................................................5
1.4 ElectricitySupply.............................................5
1.5 LocationofBoiler..............................................5
1.6 Air Supply.......................................................7
1.7 Flue Systems..................................................7
1.8 FlueTerminalLocation......................................8
1.9 TheSystem.....................................................9
2. Installation...................................................12
2.1 Unpack&PreparetheBoiler.............................12
2.2 InstalltheFlue...............................................13
2.3 ConnectthePowerSupplyCable.....................15
2.4 InstalltheOptionalProgrammer.......................16
2.5 ConnecttheGasSupply.................................16
2.6 ConnecttheWaterSupply..............................17
3. Commissioning............................................18
3.1 CommissiontheBoiler....................................20
3.2 FinalAdjustments..........................................21
3.3 AdvisetheUser..............................................21
4. To Service the Boiler & Component
Replacement.................................................22
4.1 GeneralAccess.............................................22
4.2 ToServicetheBoiler......................................23
4.3 ComponentReplacement..............................23
4.3.1 ElectronicControlBoard...........................24
4.3.2 AirPressureSwitch...................................24
4.3.3 Electrode..............................................25
4.3.4 Burner30-80............................................25
4.3.5 Injector30-80...........................................25
4.3.6 CombustionChamberInsulation30-80.......25
4.3.7 GasValve30-80.......................................26
4.3.8 Burner100................................................27
4.3.9 CombustionChamberInsulation100...........27
4.3.10GasValve100...........................................28
4.3.11Injectors100.............................................29
4.3.12Fan&FlueHood........................................29
4.3.13TemperatureSensor.................................30
4.3.14OverheatThermostat................................30
4.3.15HeatExchanger........................................31
5. FunctionalWiringDiagram.............................32
6. WiringDiagrams.............................................33
7. FaultFinding....................................................34
8. ShortListofSpares.........................................36
FlueKits..............................................................38
SystemandOtherKits......................................40
PottertonisamemberoftheBenchmarkinitiativeandfully
supportstheaimsoftheprogramme. Benchmarkhasbeen
introduced to improve the standards of installation and
commissioningofcentralheatingsystemsintheUKandto
encourage the regular servicing of all central heating
systems to ensure safety and efficiency.
Important–Failuretoinstallandcommissionthisappliance
tomanufacturer’sinstructionsmayinvalidatethewarranty.
This note does not affect your statutory rights.
Theboilermodelandserialnumberaregivenontheboiler
data label which is located on the right hand side of the
chassis and visible after opening the controls door.
The models covered by these instructions are:-
Suprima 30L - G.C. No. 41 590 42
Suprima 40L - G.C. No. 41 590 43
Suprima 50L - G.C. No. 41 590 44
Suprima 60L - G.C. No. 41 590 45
Suprima 70L - G.C. No. 41 590 46
Suprima 80L - G.C. No. 41 590 47
Suprima 100L - G.C. No. 41 590 48
POTTERTON G.C. No. 41 590 42
9016
BOILER CODE No. ALVG101 0003
SUPRIMA 30 L
SUP263A

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Publication No. 5102696 3
MaximumWorkingHead 30.5 m (100 ft)
MinimumWorkingHead 150 mm (6 in)
GasSupplyPressure 20mbar
GasSupplyConnection Rc. ½ (½ in BSP Female) (30 - 80 models)
15mmcopper tail (100 model)
MaximumFlowTemperature 82°C
Flow/ReturnConnections 22mmCopper
WaterContent 1.7 litres (0.37 gal) - 30, 40 & 50 Models
2.1 litres (0.46 gal) - 60, 70, 80 & 100 Models
ApplianceLift Weight 26.0 kg (57.3 lbs) - 30, 40 & 50 Models
30.2 kg (66.6 lbs) - 60, 70 & 80 Models
34.6 kg (76.3 lbs) - 100 Model
ApplianceWeight 32.0 kg (70.0 lbs) - 30, 40 & 50 Models
Installed - Dry 35.4 kg (78.1 lbs) - 60, 70 & 80 Models
39.7 kg (87.5 lbs) - 100 Model
Electricity Supply 230v ~ 50Hz Fused at 3A
InternalFuse Type3.15AT
PowerConsumption 80Watts(excludingpump)
Classifications CAT 12H 2HG2020mbar IP20
C12, C32
TechnicalData
Nominal Boiler Ratings
Technical Data
Boiler
models Input Burner setting pressure Gas Rate
kW
8.8
11.7
14.7
17.6
20.5
23.4
28.7
Btu/h
30000
40000
50000
60000
70000
80000
98000
Output kW
11.0
14.7
18.3
22.0
25.6
29.3
35.9
Btu/h
37500
50000
62500
75000
87500
100000
122500
inwg
3.70
4.50
4.10
3.70
5.35
5.56
5.54
m³/h
1.05
1.40
1.75
2.10
2.45
2.80
3.42
ft³/h
37.1
49.3
61.8
74.2
86.4
98.7
120.9
Injector Size
mm dia.
2.8
3.1
3.5
3.9
3.9
4.1
3.2
30
40
50
60
70
80
100
mbar
9.3
11.2
10.3
9.2
13.4
13.9
13.6
SAFETY, PERFORMANCE & QUALITY
Suprimaboilers havebeenassessedbya GovernmentappointedNotified
Body and shown to meet the 'Essential Requirements' of the European Gas
ApplianceDirective.
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.
SEDBUK Declaration for Suprima
Model Seasonal Efficiency
(SEDBUK) (%)
30L 78.0
40L 78.5
50L 78.1
60L 78.1
70L 78.6
80L 78.8
100L 78.0
This value is used in the UK
Government's Standard Assessment
Procedure (SAP) for energy rating of
dwellings. The test data from which it
hasbeencalculatedhavebeencertified
by 0063.

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Publication No. 5102696
4
Introduction
Introduction/InstallationRequirements
GasSafety(Installation&Use)Regulations1998.
Thisappliancemustbeinstalledandservicedbyacompetent
person,in accordancewiththe aboveregulations.
IntheUK'Corgi'RegisteredInstallers(includingtheregions
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
theregulationsarecompliedwith.
Suprima boilers are fully automatically controlled, wall
mounted, fan powered, balanced flue appliances using a
cast iron heat exchanger and are available in outputs
ranging from 8.8 - 28.7 kW (30,000 - 98,000 Btu/h)
The boilers are designed for use on fully pumped open
ventedorsealedwatersystemswithan indirect hot water
cylinder.
THEY MUST NOT BE CONNECTED TO A DIRECT
CYLINDER.
The boilers are for use on Natural Gas (G20) only.
SamplesoftheSuprimagasboilershavebeenexamined
by Gastec, 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
Directive72/23/EECandshowscompliancewiththeElectro
Magnetic Compatibility Directive 89/336/EEC, the Boiler
EfficiencyDirective92/42/EECandarethereforepermitted
to carry the CE Mark.
Delivery&KitsAvailable
The unit is delivered in two packages (1) the boiler with
fittingsand(2)theflue/terminalassembly.Seepages38&
39 for flue options.
VariouskitsareavailablefortheSuprimarangeofboilers,
see pages 40 & 41.
1. Installation Requirements
1.1 Health and Safety Information for the
Installer and Service Engineer
UndertheConsumerProtectionAct1987andSection6of
theHealthandSafetyatWorkAct1974,wearerequiredto
provideinformation onsubstances hazardousto health.
Small quantities of adhesives and sealants used in the
productarecuredandpresentnoknownhazards.
Thefollowingsubstancesarealsopresent.
Insulation and Seals
Material -ManMadeMineralFibre.
Description - Boards, Ropes, Gaskets.
KnownHazards -Somepeoplecansufferreddening
and itching of the skin. Fibre entry into the eye will
cause foreign body irritation which can cause severe
irritationtopeoplewearingcontactlenses.Alsoirritation
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
toarisefollowingharshabrasion.In general,normal
handlinganduse willnotpresenthighrisk,followgood
hygienepractices,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 1998 and the
current issue of:-
The Building Regulations, Building Standards (Scotland)
Regulations, Local Building Regulations, Model and local
WaterUndertakingBye-laws,IEEWiringRegulationsand
Health & Safety Document No. 635 "The Electrician At
WorkRegulations1989".

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Publication No. 5102696 5InstallationRequirements
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.
Powerconsumptionisapproximately150W(inc.pump).Theremustbeonlyonecommonisolatorfortheboileranditscontrol
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:THISAPPLIANCEMUSTBEEARTHED.
Intheeventofanelectricalfaultafterinstallationoftheboiler,preliminaryelectricalsystemschecksmustbecarriedouti.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.
If the sealed system kit is being used, this should be installed first. See instructions supplied with kit.
Theboilermustbeinstalledsothattheflueterminalisexposedtotheexternalair.Itisimportantthatthepositionoftheterminal
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
25mmtocombustiblematerial.Ametalsleeveshouldbeinstalledtosurroundtheflueducttoprovidea25mmannularspace.
Furtherguidance is giveninBS5440:1:2000, sub-clause 4.4.
Ifthe boileris tobe installedinatimberframed buildingit shouldbe fittedinaccordancewiththe Instituteof GasEngineers
documentIGE/UP/7/1998(also,BritishGasServicepublicationPart19-BuildingandKitchenWork).Ifindoubtadvicemust
be sought from Potterton.
Theboilermaybeinstalledinanyroom,althoughparticularattentionisdrawntotherequirementsofthecurrentIEEWiring
Regulations and, in Scotland, the electrical provisions of the Building Standards applicable in Scotland with respect to the
installationoftheboilerinaroomcontainingabathorshower.Wherearoom-sealedapplianceisinstalledinaroomcontaining
abathorshower,anyelectricalswitchorappliancecontrol,utilisingmainselectricityshouldbesosituatedthatitcannotbe
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.
Anexistingcupboardorcompartmentmaybeusedprovidedthatitismodifiedforthepurpose.Detailsofessentialfeatures
of cupboard/compartment design including airing cupboard installations are given in BS6798 and BS5546 and should be
compliedwith.
The boiler requires only the clearances shown on Page 6, after installation.

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Publication No. 5102696
6 InstallationRequirements
Fig. 1

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Publication No. 5102696 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.
1.6.1 Ventilated Cupboard/Compartment: Ifthe boiler is installedina cupboard orcompartment(with the exception
ofthoseinstallationscoveredbySection1.6.2),permanentairventsarerequiredinthecupboardorcompartment,
oneathigh level and oneatlowlevel, either direct to theoutsideair or to a room.Bothhigh level and low levelair
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.
Models: 30: 99 cm² 40: 133 cm² 50: 169 cm²
60: 198 cm² 70: 231 cm² 80: 264 cm² 100: 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.
1.6.2 Unventilated Compartment: The30,40and 50modelscan beinstalledin an unventilatedcompartment
providingthefollowingconditionsare met and no other heat sources are present within the compartment:
MaximumHorizontalflue length from turret: 560mm
Minimumclearancesforalternativeconfigurations
Front 280mm or Front 490 mm
Side 75 mm Side 175mm
Bottom 250mm Bottom 100mm
Top 450mm Top 265mm
1.7 Flue Systems
Horizontal • Theflue/terminalassemblysuppliedissuitable fora wallthickness ofbetween 150mm and300
mm.
• A flue/terminal assembly suitable for a wall thickness of up to 550 mm is also available.
• Both the flue/terminal assemblies are telescopic and the minimum lengths (150 mm/6 in) are
achieved by cutting. Ensure that the same length is removed from the inner and outer tubes to
maintaina20 mm overlap (minimum).
• 1 m flue extensions are available.
• Under no circumstances should the total flue length exceed - 3.4 m, 30 - 80 models.
-0.68m,100modelNobends
allowed.
Vertical 1. Twin Tube system, 30 - 80 models only.
Maximum actual length 7 m (7 extensions)
Maximum equivalent resistance = 7 m
2. Vertical Concentric system.
30 - 80 models - Maximum actual length 3.4 m, equivalent resistance = 3.4 m.
100 model - Maximum actual length 1.4m, No bends allowed.
CombinationFlueSystem
• Combined horizontal & vertical concentric system for 30 - 80 models only.
Maximum actual length 3.4 m, maximum equivalent length 3.4 m.
Note: All flue lengths quoted refer to straight lengths. For the effects of bends and offsets see Section 2.2 'Install the
Flue'or theappropriate flueinstructions.
InstallationRequirements

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Publication No. 5102696
8
• Where 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), this should be fitted centrally
about the terminal.
Note: Where a flue terminal is installed less than
1 metre from a plastic, or painted gutter, or 500
mm 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
combustionarefoundtobere-enteringanybuilding,
the appliance MUST be turned OFF
IMMEDIATELY.
1.8 Flue Terminal Location
InstallationRequirements
Fig. 2
M
G
G
H
F
L
G
AAF
J
K,N
D
E
J
Likely flue positions requiring
a flue terminal guard
C
Q
AG
K,N
G
FLU0002A
P
S
R
FannedDraughtBalancedFlue
ADirectly below an opening, air brick,
opening window etc
BAbove an opening, air brick, opening window, etc
CHorizontally to an opening, air brick,
opening window etc
DBelow a gutter, or sanitary pipework
EBelow the eaves
FBelow a balcony or carport roof
GAbove ground, roof or balcony level
HFrom vertical drain/soil pipe work
JFrom an internal or external corner
KFrom a surface facing a terminal
LVertically from a terminal on the same wall
MHorizontally from a terminal on the same wall
NFrom a terminal facing the terminal
PFrom an opening in a carport (e.g. door, windows)
into the building
QFrom adjacent wall to flue (vertical only)
RFrom internal corner to flue (vertical only)
SBelow eaves or balcony (vertical only)
Terminal Position with Minimum Distance (mm)
Note: The distance from a fanned draught appliance terminal installed
paralleltoa boundary maynotbe lessthan300 mminaccordance with
the diagram on the left.
300
300
300
75
200
200
300
150
300
600
1500
300
1200
1200
210
230
600
Top View Rear Flue Top View Side Flue
Terminal
Assembly
Property Boundary Line
Fanned DraughtFanned Draught
300 min. 300 min.
FLU0005A
Reduced Clearances
This range of boilers has been tested and approved for use with certain
clearances less than those shown above.
Only one of these reductions may be used on a single installation.
DBelow a gutter, or sanitary pipework 25
EBelow the eaves 25
FBelow a balcony or carport roof 25
HFrom vertical drain/soil pipe work 25
JFrom an internal or external corner 25

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Publication No. 5102696 9InstallationRequirements
1.9 The System
Beforeinstallinganewboilertoanexistingsystemtreatthe
systemwithanappropriatedescaling/flushingagentasper
the instructions supplied with the treatment package. It is
recommendedthatanycorrosioninhibitorsanddescalers/
flushing agents used are manufactured by Fernox or
BetzDearborn.
If plastic pipe is used for the central heating circuit there
mustbearunofatleast2mofuninsulatedcopperpipefrom
theboiler flowandreturn connections.
TheboilermustbeusedonIndirectFullyPumpedsystems
only, which may be sealed or open vented - See Page 12
forpumprequirements.
Thesystemshouldbedesignedsothatthemaximumstatic
headdoesnotexceed30.5m(100ft)andaminimumof150
mm(6in).Theflowpipefromtheboilermustalwaysbelevel
toorhigherthanthereturn pipe.
On all systems the pump live connection should be wired
tothe boiler terminal block,itwill then becontrolledbythe
pumpover-run.Thiswillensurethatthepumpwillcontinue
torunafterboilershutdownifthewatertemperatureishigh,
thus preventing nuisance operation of the overheat
thermostat.
Itisimportantthatwhereelectricallyoperatedzonevalves
are used the boiler is wired so it does not cycle when the
zone valves are closed. Also, systems fitted with controls
thatclosebothhotwaterandcentralheatingcircuitswhile
theboiler isstillhot, mustbefitted withaby-pass circuitto
dissipate the residual heat from within the boiler.
IfathreeportvalveisusedasshowninFig.5aby-passis
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
fromtheboilerconnectionsshouldbegreaterthan4metres
of22mmpipe.Itshouldbefittedwithalockshieldvalveand
beadjustedtomaintainaminimumflowthroughtheboiler
of 4.5 litres/min (1 gal/min).
Systems fitted with controls which allow the boiler to
operatewhenboththehotwaterandcentralheatingcircuits
areclosed(i.e.mechanicallyoperatedthermostaticcontrol
valves)mustbefittedwithaby-passcircuit(2mmin.length
of22mmdia.pipe)andcapableofmaintainingaminimum
waterflowratethroughtheboilerof9litres/min(2gal/min).
A suggested method of meeting these requirements by
usingabathroomradiatorfittedwithtwolockshieldvalves
is shown in Fig. 5. Additional system information can be
foundintheControlSystems,pipeworkandWiringGuide.
Drain off taps should be fitted in the pipework close to the
boiler and in the low points of the system.
Note:Althoughthesystemcanbeemptiedusingthedrain
off taps installed in the pipework around the system, to
empty the boiler it is necessary to remove the drain off
screwpositioned ontheheatexchanger.
Sealed Systems
Note: If the sealed system kit is Not being used the
installation must comply with the following requirements.
Installation
The installation must comply with the requirements of BS
6798:1987andBS5449:Pt1.TheBritishGaspublication
"BritishGasSpecificationforDomesticWetCentralHeating
Systems" should also be consulted.
PressureReliefValve
Anon-adjustablespring-loadedpressurerelief valve,preset
tooperateat3bar(45lbf/in²)shallbeused.Itmust comply
withBS 6759: Pt1. and includeamanual testingdevice.It
shall be positioned in the flow pipe either horizontally or
verticallyupwardsandclosetotheboiler.Noshut-offvalves
aretobeplacedbetweentheboilerandthesafetyvalve.The
valve should be installed with a discharge pipe which
permitsthesafedischargeofsteamandhotwatersuchthat
nohazardto persons or damage to electricalcomponents
is caused.
PressureGauge
A pressure gauge incorporating a fill pressure indicator,
coveringtherange0-4bar(60lbf/in²)shallbefittedtothe
system.Itshouldbeconnectedtothesystem,preferablyat
thesamepointastheexpansionvessel.Itslocationshould
be visible from the filling point.
ExpansionVessel
AdiaphragmtypeexpansionvesseltoBS4814:Pt1.shall
befittedclosetotheinletsideofthepump.Theconnecting
pipework should not be less than 15 mm. 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
systemabovetheexpansionvessel).Tosizetheexpansion
vesselit is first necessarytocalculate the volume ofwater
inthesysteminlitres. Thefollowing volumesmay beused
asaconservative guide to calculating the system volume.
BoilerHeatExchanger: 2.1 litres
SmallBorePipework: 1 litre per kW of system
output
MicroBorePipework: 7 litres
SteelPanelRadiators: 8 litres per kW of system
output
LowWaterCapacityRadiators: 2 litres per kW of system
output
HotWaterCylinder: 2 litres

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Publication No. 5102696
10
Cylinder
The hot water cylinder must be an indirect coil type or a
directcylinderfittedwithanimmersioncalorifiersuitablefor
operatingatagaugepressureof0.3bar(5lbf/in²)inexcess
ofsafetyvalvesetting.Singlefeedindirectcylindersarenot
suitable for sealed systems.
MethodofMake-upforsealedsystems
Provision shall be made for replacing water loss from the
system either:-
i) fromamake-upvesselortankmountedinaposition
higherthanthetoppointofthesystem,andconnected
through a non-return valve to the system on the
returnsideofthehotwatercylinderorthereturnside
of all heat emitters, see Fig.6.
or
ii) whereaccesstoamake-upvesselwouldbedifficult
by using the mains top up method or a remote
automaticpressurisationandmake-upunitasshown
in Figs. 3 & 4.
MainsConnection
Thereshallbenoconnectiontothemainswatersupplyor
tothewaterstoragetankwhichsuppliesdomestichotwater
eventhoughanon-returnvalve,withouttheapprovalofthe
LocalWaterAuthority.
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 of an accepted type to be fitted in this order
from the system mains, see Fig. 3.
1.5
1.0
V x 0.087
VesselChargePressure(bar)
Initial System Pressure (bar)
Expansion Vessel Volume (litres)
0.5
1.0
V x 0.11
Table 1.
If the system is extended, the expansion vessel volume
mayhavetobeincreasedunlessprovisionhasbeenmade
for extension. Where a vessel of the calculated size is not
available, the next available larger size should be used.
Theboiler 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.
Fig. 4
Fig. 3
InstallationRequirements

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Publication No. 5102696 11
Fig. 5
Fig. 6
InstallationRequirements

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Publication No. 5102696
12 InstallationRequirements/Installation
CirculationPumpSelection
The resistance through the heat exchanger
whenoperatingwithawaterflowrateproducing
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,theresistancethroughthem,quotedin
their manufacturers literature must be taken
intoaccount.Thepumpmaybefittedoneither
thefloworreturnandMUSTbewireddirectlyto
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
l/min
11.5
15.2
19.2
22.9
26.7
30.5
37.4
mbar
17.5
35.3
44.9
59.5
80.9
105.3
147.0
m
0.18
0.36
0.46
0.61
0.83
1.08
1.50
30
40
50
60
70
80
100
2. Installation
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. Carefullyunpacktheboiler.
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. Placethemountingtemplateintheproposedboilerpositionensuringthatitislevel.Minimumclearancesareaccounted
for on the template.
6. Mark the flue hole, remove the template and carefully cut the flue hole through the wall.

Supplied By www.heating spares.co Tel. [phone]
Publication No. 5102696 13Installation
Boiler
Boiler Securing Point
Flue Tube
Minimum Clearance
SUP0010B
410mm Minimum Clearance
660mm Minimum Clearance
Literature
Pack
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fdthyjkllkhklkyj
fdthyjkllkhklkyj
F
R
Boiler
Mounting
Bracket
Fixings
Poly Bag
Boiler
Securing
Clip
Boiler
Mounting
Bracket
Wall
Template
Fig. 7
7. Replacethetemplatecentrallyoverthehole
(ensure template is level), mark two screw
fixingholepositionsforthemountingbracket
and one for the securing point.
8. Remove the template, drill (7 mm drill) and
plugthethreeholes.
9. 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
mountingbracket(thispreventstheboiler
from being accidently lifted off the the
mountingbracket),seeFig.7.
To square the boiler to the wall adjust the
boileralignementscrewsonthebackpanel
of the boiler.
11.The third screw provided is also to prevent
theboiler from beingliftedoff 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:Thereisprovisionforananti-theftsecuring
point (sales code: SUPKITP) which may be
usedifrequired.
2.2 Install the Flue
Maximum equivalent flue lengths are as
follows: 30 - 80 Models - 3.4m, 100 Model -
0.68m (no bends allowed).
These instructions are for rear and side flue
applications.
RearFlue
1. Measure the wall thickness and add
66mm(or 106mm for installations using
the System Boiler or Stand Off Kits).
Side Flue
1. DeterminetheXdimension (wallthickness
+ distance to boiler centreline).
For both Rear & Side Flues
2. Extend the telescopic flue to the required
length, minimum 20 mm overlap.
3. Drillthroughthepilot hole and secure with
self tapping screw.
4. Wraptape around thejointon 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
screwsandturnthe elbow to the required
positionandre-tightenscrews.Ensure
that the seals are still correctly located.

Supplied By www.heating spares.co Tel. [phone]
Publication No. 5102696
14 Installation
7. Slide the flue back until it engages in the
elbowbayonetconnection, twist anti-
clockwise to lock.
8. Drill through pilot hole and lock flue in
position with the self tapping screw
provided.
9. Make good the wall around the flue, both
outsideand inside.
For extension kits refer to pages 38 & 39. If a
HorizontalExtensionisrequiredthisMUSTbe
combinedwithaStandardFlueasshownbelow
in the Maximum Flue Length Guide.
If a in-line bend is required in the flue the
followingrules apply:
A 90° in-line bend is the equivalent to a 1m
length of flue.
A 135° in-line bend is the equivalent to a ½m
length of flue.
The maximum equivalent flue resistance
allowed when using bends is:
30-80models-3.4m,100model-notallowed.
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
theinnerandoutertubesto maintain a 20 mm
overlap(minimum).
For further information see the publications
supplied with the flue system.
Fig. 8

Supplied By www.heating spares.co Tel. [phone]
Publication No. 5102696 15
PIN 87ARXXX
POTTERTON G.C. No. 41 590 42
Input (GROSS) Q =
11.00
37500 kW Btu/h
8.80
30000 kW Btu/h
9.30
3.70 mbar
in. wg
1.05
37.10 cu. m/h cu. ft/h
Output P =
Burner Pressure (HOT)
Gas Rate
Injector Size 2.8mm Dia.
Type - C C C PMS = 3.0 bar
230V ~ 50Hz.
80W 3A Fuse
THIS APPLIANCE IS INTENDED EXCLUSIVELY TO
BE INSTALLED ON A SUPPLY
WITH A GOVERNED METER
Baxi Heating Ltd.
5105714
COUNTRY OF DESTINATION - GB, IE.
01
0086
IP 20
NO x CLASS 3
9016
BOILER CODE No. ALVG101 0003
SUPRIMA 30 L
12 32
2H
2H - G20 - 20 mbar
71
SUP0262B
Installation
Fig. 9
2.3 Connect the Power Supply
Cable
1. Cable clamping is provided on the front of
thecontrolspanel.Feedthecablesupand
over the back of the chassis, through the
clamp and into the terminal connection.
Connectthewires,browntoL,bluetoNand
green/yellowtoearth( ).
Note:Whenconnectingthepowersupply
cable, ensure that the length of the earth
wireis such, that ifthepower supply cable
pulls out of the cable clamp the live and
neutralwiresbecometautbeforetheearth
wire.
2. Thepumpwiringshouldberoutedthrough
the hole in the base of the rear cover,
throughthe cableclamp andconnected to
theterminalconnection.
3. Takeupexcessslackinthecablesbetween
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
hingefreely.Checkbyopeningthecontrol
panel.
Iffittingtheoptionalintegralprogrammergo
to section 2.4 before performing steps 4
and5below.
4. Securethecontrolsassemblytothechassis
usingthescrew previously removed.
5. Carry out preliminary electrical system
checks i.e. Earth Continuity, Short Circuit,
Polarity and Resistance to Earth.
FrostThermostat:
If a Frost Thermostat is to be fitted, the
connections should be made in the wiring
external to the boiler.
TheFrostThermostatshouldbeconnected
betweenthePermanentLive&SwitchLive
in the mains terminal block on the boiler.
Donotswitchontheelectricitysupplyat
thisstage.

Supplied By www.heating spares.co Tel. [phone]
Publication No. 5102696
16
Fig. 10
Fig. 11
Installation
2.4 InstalltheOptional
Programmer
1. Install the programmer as shown in the
instructions supplied with it.
2.5 Connect the Gas Supply
Ensurethatthegassupplyisisolated.Connect
the gas supply using a suitable adaptor to the
gas valve or 15 mm copper tail (100 model).
Important:
To prevent damage to the 'O' ring,
do not solder the fitting
whilst assembled to the gas valve.
Thepipediameter required will depend on the
boiler model and the pipe length from the gas
meter. Ensure that the gas supply pipe is
selectedinaccordancewithBS6891sothatan
adequate gas supply to the boiler is provided.
Do not turn the gas supply on at this stage.
Front
View
28
20 100
SUP0021B
40
85
28
Gas
Valve
All Dimensions
in mm
When Soldering
Remove 'O' Ring Side View
DO NOT
Solder The
Fitting Whilst
Assembled To
The Gas Valve
Fitting
Gas
Valve
Closed Open
Gas Valve Gas Valve
Securing
Screws
Gas Cock
Rc ½"
½" B.S.P.
Female
100model 30 - 80 models

Supplied By www.heating spares.co Tel. [phone]
Publication No. 5102696 17
Fig. 12
Installation
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
close to the boiler and at the lowest points
in the system.

Supplied By www.heating spares.co Tel. [phone]
Publication No. 5102696
18
3. Commissioning
Fig. 13
Commissioning
PIN 87ARXXX
POTTERTON G.C. No. 41 590 42
Input (GROSS) Q =
11.00
37500 kW Btu/h
8.80
30000 kW Btu/h
9.30
3.70 mbar
in. wg
1.05
37.10 cu. m/h cu. ft/h
Output P =
Burner Pressure (HOT)
Gas Rate
Injector Size 2.8mm Dia.
Type - C C C PMS = 3.0 bar
230V ~ 50Hz.
80W 3A Fuse
THIS APPLIANCE IS INTENDED EXCLUSIVELYTO
BE INSTALLED ON A SUPPLY
WITH A GOVERNED METER
Baxi Heating Ltd.
5105714
COUNTRY OF DESTINATION - GB, IE.
01
0086
IP 20
NO x CLASS 3
9016
BOILER CODE No. ALVG101 0003
SUPRIMA 30 L
12 32
2H
2H - G20 - 20 mbar
71
30 L Model
Shown
50 L Model
Shown
Gas
Valve
50 L
Model
Shown
SUP264A
Gas Pressure
adjuster

Supplied By www.heating spares.co Tel. [phone]
Publication No. 5102696 19
Fig. 14
Commissioning
Important
Whenchecking for gassoundnessopen
all windows and doors in the room.
Extinguish all naked lights, cigarettes, pipes, etc.
Important
Thecommissioningandboileradjustmentmust
only be carried out by a suitably qualified
personnel. Potterton offer this service on a
chargeablebasis.
Gas Pressure
adjuster
100 model shown

Supplied By www.heating spares.co Tel. [phone]
Publication No. 5102696
20
3.1 Commission the Boiler
Commissioning
OpenVentedSystems-Removethepumpandflush
thesystemthoroughlywithcoldwater.Re-fitthepump.
Fill and vent the system then check for leaks.
Sealed Systems - Remove the pump and flush the
systemthoroughlywithcoldwater.Re-fitthepump.Fill
andventthesystemuntilthepressuregaugeregisters
1.5 bar (21.5 lbf/in²) and check for leaks.
IMPORTANT:Thepressurereliefvalveisfactorytested
anddoesnotneedtestingduringthecommissioningof
the boiler. It must not be used to reduce system
pressureasitmaycausedebrisinthesystemtofoulthe
valve.
AllSystems
Warning:Beforelightingtheboiler,ensurethatthe
outerwhitecasehasbeen correctly fittedandthat
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.
Preliminaryelectricalsystemchecks
Thesechecksmustbecarriedoutbeforeattemptingto
light the boiler.
Theyare:- EarthContinuity,ShortCircuit,Polarity
& Resistance to Earth.
Commission
1.The whole of the gas installation must be checked
forsoundnessandpurgedinaccordancewithBS
6891.
2. Setthe boiler temperature control knob to 'O'
Standby.
3. Turnthe boiler gas service cocktothe 'On' position
and ensure that the main gas supply is turned 'On'.
4. Makesurethatthesystemisfullofwaterandthatthe
pumpandradiatorisolatingvalvesareopen.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'
positionand thattheroom andcylinder 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)theboilercontrolswillgoto'Lockout'andthe
upperRedLEDonthecontrolpanelwillgotoarapid
flashingmode.Tore-startthelightingsequencepress
theresetbuttonon the control panel. There will be a
short delay before the lighting sequence starts.
WhentheburnerflamehasestablishedlowerGreenLED
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 FLASHING ON
(Boiler set to STNDBY, 2 Per Sec.
Temp. Control set to 'O' Off)
Ext. Call for Heat FLASHING OFF
(STNDBY switch to ON, 2 Per Sec.
Temp. Control set to Max.)
Ignition FLASHING OFF
(i.e. Gas and Sparks ON) 16 Per Sec.
FLAME Detected ON OFF
Boiler Temperature FLASHING ON
Control Satisfied 2 Per Sec.
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
temperaturecontrolto'Standby'anddrainthesystem
whilst still hot.
Note: Shouldtheboiler fail to operatecorrectlyreferto
theFaultFindingGuideandtheboilerwiringdiagramfor
furtherinformation.
10.Re-filland vent the system making a final checkfor
leaks.
11. On sealed systems adjust to the correct cold fill
pressure. Set the pressure gauge pointer to the
system design pressure.
12.Ifaby-passcircuitisfittedtheby-passvalveshould
be adjusted so as to maintain sufficient water flow
through the boiler to ensure that the overheat
thermostatdoesnotoperateundernormalconditions.