Potterton Suprima 80 HE Installation and maintenance instructions

© Baxi Heating UK Limited 2005
Installation & Service Instructions
Only a flue approved for the Suprima HE can be used.
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
Suprima
30 - 80 HE
Condensing
Central Heating Boiler

2intelligently applied technology © Baxi Heating UK Limited 2005
Contents
1. Introduction.....................................................4
2. Technical Data.................................................6
3. Installation Requirements..............................8
3.1 General Information........................................8
3.2 Legislation, Standards & Codes of Practice....8
3.3 Gas Supply......................................................8
3.4 Electricity Supply.............................................9
3.5 Location of Boiler............................................9
3.6 Condensate Disposal....................................10
3.7 Air Supply......................................................10
3.8 Flue Systems................................................10
3.9 Water Circulating Systems...........................14
4. Installation.....................................................18
4.1 Unpack, Prepare the Wall & Boiler................18
4.2 Install the Flue...............................................19
4.3 Electrical Connections..................................20
4.4 Connect the Gas Supply...............................21
4.5 Connect the Water System...........................21
4.6 Connect the Condensate Drain.....................21
5. Wiring Diagrams............................................22
6. Commissioning.............................................24
6.1 Commission the Systems.............................24
6.2 Commission the Boiler..................................24
6.3 Flush the System..........................................24
6.4 Final Adjustments.........................................25
6.5 Advise the User.............................................25
6.6 Documentation.............................................25
7. Control Sequence.........................................26
8. Fault Finding Guides.....................................27
9. Servicing & Parts Replacement...................34
9.1 Servicing Procedure.....................................34
9.2 General Access............................................36
9.3 PCB Enclosure.............................................36
9.4 Gas Valve......................................................36
9.5 Air Pressure Switch.......................................37
9.6 Spark Igniter..................................................37
9.7 Flow/Casting Sensors...................................37
9.8 Overheat Sensor...........................................37
9.9 Fan & Flue Hood...........................................38
9.10 Electrodes/Burner.........................................39
9.11 Injector..........................................................39
9.12 Combustion Chamber Insulation...................40
9.13 Condensate Trap...........................................41
9.14 Primary Heat Exchanger...............................42
9.15 Secondary Heat Exchanger..........................43
10. Short Spares List......................................44
Benchmark Commissioning Checklist............46
Building Regulations and the Benchmark
Commissioning Checklist
Building Regulations (England & Wales) require
notification of the installation of a heating appliance to
the relevant Local Authority Building Control
Department. From 1 April 2005 this can be achieved via
a Competent Persons Self Certification Scheme as an
option to notifying the Local Authority directly. Similar
arrangements will follow for Scotland and will apply in
Northern Ireland from 1 January 2006.
CORGI operate a Self Certification Scheme for gas
heating appliances.
These arrangements represent a change from the
situation whereby compliance with Building Regulations
was accepted as being demonstrated by completion of
the Benchmark Logbook (which was then left on site
with the customer).
With the introduction of Self Certification Schemes, the
Benchmark Logbook is being withdrawn. However, a
similar document in the form of a commissioning
checklist and service interval record is incorporated at
the back of these instructions.
Potterton is a member of the Benchmark initiative and
fully supports the aims of the programme. Its aim is to
improve the standards of installation and commissioning
of central heating systems in the UK and to encourage
the regular servicing of all central heating systems to
ensure safety and efficiency.
Building Regulations require that installations should
comply with manufacturer's instructions. It is therefore
important that the commissioning checklist is completed
by the installer. The relevant section of Building
Regulations only relates to dwellings. Therefore the
checklist only applies if the appliance is being installed
in a dwelling or some related structure.
The flowchart opposite gives guidance for installers on
the process necessary to ensure compliance with
Building Regulations.

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© Baxi Heating UK Limited 2005
Choose Building
Regulations Notification
Route
Contact your relevant Local
Authority Building Control
(LABC) who will arrange
an inspection or contact
a government approved
inspector
LABC will record the data
and will issue a
certificate of compliance
CORGI will record the data and
will send a certificate of
compliance to the property
You must ensure that the
notification number issued by
CORGI is writen onto the
Benchmark Checklist
Scheme Members only
Call CORGI on: 0870 88 88 777
or log onto:
www.corgi-notify.com
within 10 days
If you notify via CORGI Scheme,
CORGI will then notify the
relevant Local Authority
Building Control Scheme
on member's behalf
Complete the
Benchmark Checklist
Install and Commission this
appliance to manufacturer's
instructions
Competent Person's
Self Certification Scheme Building Control
Installer Notification Guidelines

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1. Introduction
Potterton Suprima HE
Suprima 30 HE G.C. No. 41 075 35
Suprima 40 HE G.C. No. 41 075 36
Suprima 50 HE G.C. No. 41 075 37
Suprima 60 HE G.C. No. 41 075 38
Suprima 70 HE G.C. No. 41 075 39
Suprima 80 HE G.C. No. 41 075 40
Suprima HE boilers are fully automatically controlled,
wall mounted, fan powered, balanced flue condensing
boilers using a cast iron primary heat exchanger.
Suprima HE boilers meet the requirements of Statutory
Instrument “The Boiler (Efficiency) Regulations 1993
No 3083” and deemed to meet the requirements of
Directive 92/42/EEC on the energy efficiency
requirements for new hot water boilers fired with liquid
or gaseous fuels:-
Type test for purpose of Regulation 5 certified by:
Notified Body 0087.
Product/Production certified by:
Notified Body 0086.
For use with Natural Gas (G20) only at 20mbar and for
use in GB/IE only.
CORGI
All CORGI registered installers carry a CORGI
identification card and have a registration number. You
can check your installer is registered by:-
• Telephoning 0870 401 2300
• Writing to 1 Elmwood, Chineham Business Park,
Crockford Lane, Basingstoke, RG24 8WG.
• Check online at www.corgi-gas-safety.com
Identification
To gain access to the identification labels, pull the door
down.
The data label is on a swing out plate located just
above the operating lights and temperature control
knob.
A seven digit version of the serial number is located on
the operating label attached to the rear of the door.
© Baxi Heating UK Limited 2005
Important Installation Notes
The boiler is suitable for use with fully pumped
open vented and sealed systems with an indirect
coil type high efficiency cylinder.
The gas type, supply size and pressure must be
checked for suitability before connection.
Failure to install the condensate discharge
pipework correctly could affect the reliable
operation of the boiler.
For the boiler to operate correctly all air must be
vented from the system prior to commissioning
and the system itself must be suitably vented.
The system must be designed to always provide
a route for water to circulate between the boiler
flow and return.
For optimum boiler performance, pump
performance must meet the requirements shown
on Page 15.
Failure to flush and add inhibitor to the system
may invalidate the boiler warranty.
Failure to commission the boiler correctly may
result in the installer being charged for any visits
made by Baxi Potterton.
© Baxi Heating UK Limited 2005 All rights reserved. No part of this publication
may be reproduced or transmitted in any form or by any means, or stored in any
retrieval system of any nature (including in any database), in each case whether
electronic, mechanical, recording or otherwise, without the prior written
permission of the copyright owner, except for permitted fair dealing under
Copyrights, Designs and Patents Act 1988.
Applications for the copyright owner’s permission to reproduce or make other
use of any part of this publication should be made, giving details of the proposed
use, to the following address:
The Company Secretary, Baxi Heating UK Limited, Pentagon House,
Sir Frank Whittle Road, Derby, DE21 4XA.
Full acknowledgement of author and source must be given.
WARNING: Any person who does any unauthorised act in relation to a
copyright work may be liable to criminal prosecution and civil claims for damages.

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.
Man-Made Mineral Fibre
a) Some component parts of this boiler (insulation
pads, gaskets and rope seals) are manufactured
from man-made mineral fibre.
b) Prolonged or excessive exposure to this material
may result in some irritation to the eyes, skin or
respiratory tract.
c) It is advisable to wear gloves when handling these
items.
d) Irritant dust will only be released from the items if
they are broken up or subjected to severe
abrasion. In these instances a suitable dust mask
and goggles should be worn.
e) Always thoroughly wash hands after installation,
servicing or changing components.
f) When disposing of any items manufactured from
man-made mineral fibre care must be exercised.
g) If any irritation of the eyes or severe irritation of
the skin is experienced seek medical attention.
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Suprima HE intelligently applied technology
© Baxi Heating UK Limited 2005

Model Seasonal Efficiency
(SEDBUK) (%)
30 86.1
40 86.4
50 86.2
60 86.2
70 86.2
80 86.2
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30 HE 40 HE 50 HE 60 HE 70 HE 80 HE
Heat Input - Gross kW 10.22 13.62 17.04 20.43 23.84 27.25
Btu/h 34,877 46,465 58,129 69,717 81,343 92,968
Heat Output (Non Condensing) kW 8.82 11.78 14.76 17.72 20.68 23.63
Btu/h 30,093 40,181 50,350 60,466 70,553 80,641
Heat Output (Condensing) kW 9.50 12.64 15.66 18.83 21.89 24.94
Btu/h 32,430 43,111 53,431 64,232 74,703 85,105
Gas Rate m3/h 0.98 1.30 1.63 1.95 2.28 2.60
ft3/h 34.5 45.9 57.5 68.9 80.4 91.9
Burner Pressure - Hot mbar 8.6 10.4 9.0 8.4 11.4 12.8
in wg 3.44 4.16 3.6 3.36 4.56 5.12
Gas Supply Pressure mbar 20 20 20 20 20 20
Injector Size mm 2.8 3.1 3.5 3.9 3.9 4.1
Water Content litres 2.3 - 30, 40 & 50 2.7 - 60, 70 & 80
Boiler Weight kg 39.0 - 30, 40 & 50 42.8 - 60, 70 & 80
(Lift/Installed - Dry)
Nox Class 2 2 2 2 2 2
Maximum Working Head 30.5m (100 ft)
Minimum Working Head 150mm (6 in)
Flow Temperature Range 63°C - 82°C
Gas Supply Connection 15 mm Tail
Flow/Return Connections 22 mm Copper
Condensate System Connection 21.5 mm PP
Electricity Supply 230v ~ 50Hz
External Fuse 3A
Internal Fuse Type 3.15AT
Power Consumption 80 Watts (excluding pump)
Electrical Protection IP20
Boiler Type C12, C32, C52
Boiler Category CAT 12H2H - G20 - 20 mbar
2. Technical Data
SEDBUK Declaration for Suprima HE
This value is used in the UK
Government's Standard Assessment
Procedure (SAP) for energy rating of
dwellings. The test data from which it
has been calculated have been
certified by 0087.
© Baxi Heating UK Limited 2005

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© Baxi Heating UK Limited 2005
595 mm
400 mm
5 mm
clearance
125 mm
clearance
130 mm servicing clearance
50 mm installation clearance*
5 mm
clearance
410 mm overall
clearance
850 mm
770 mm*
overall
clearance
Fan and Flue Hood
Air Pressure Switch
Secondary
Heat Exchanger
Condensate Trap
75 mm
Gas Valve
Primary
Heat Exchanger
PCB Enclosure
Burner & Electrodes
Flow Connection Return Connection
Spark Igniter
Flow Sensor
Overheat Sensor
Casting Sensor
610 mm
servicing
clearance
260 mm
15 mm
clearance
Condensate Connection
Wiring Centre
Data Label
'O' Ring and
Clip Joints
Gas Connection
Fig. 1

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3.3 Gas Supply
The meter and supply pipes must be capable of delivering
the required quantity of gas in addition to the demand from
any other appliances in the house and must be governed
at the meter.
The pipe diameter required will depend on the boiler
model and the pipe length from the gas meter.
The gas installation should be in accordance with
BS6891.
3. Installation Requirements
3.1 General Information
Optional Extras
Various flue extensions, bends, vertical flue kits, control
accessories etc. are available as optional extras. These
are detailed in a separate publication.
Lifting
Important - This product should be lifted and handled by
two people. Stooping should be avoided, and protective
equipment worn when necessary. Carrying and lifting
equipment should be used as required, for example
when installing in a loft space.
3.2 Legislation, Standards & Codes of Practice
The boiler is suitable only for installation in GB and IE
and must be installed in accordance with the
manufacturer’s instructions and the rules in force,
and only used in a suitably ventilated location.
Any purpose provided ventilation should be checked
periodically to ensure that it is free from obstruction.
Installation, Commissioning, Service & Repair
In GB, the installation must be carried out by a
Competent Person. It must be carried out in
accordance with the relevant requirements and current
edition of:
The GAS SAFETY (Installation and Use) REGULATIONS.
The appropriate BUILDING REGULATIONS either the
Building Regulations, The Building Regulations
(Scotland), Building Regulations (Northern Ireland).
The WATER FITTINGS REGULATIONS OR WATER BYELAWS in
Scotland.
The I.E.E. WIRING REGULATIONS.
Where no specific instructions are given, reference
should be made to the relevant BRITISH STANDARD
CODES OF PRACTICE.
Reference should also be made to BRITISH GAS
GUIDANCE NOTES FOR THE INSTALLATION OFDOMESTIC
GAS CONDENSING BOILERS.
Definition of competence: A person who works for a
CORGI registered company and holding current
certificates in the relevant ACS modules is deemed
competent.
Important – Failure to install and commission this boiler
to manufacturer’s instructions may invalidate the
warranty. This does not affect your statutory rights.
In IE, the installation must be carried out by a
competent person and installed in accordance with the
current edition of:
I.S.813 “DOMESTIC GAS INSTALLATIONS”.
The current BUILDING REGULATIONS.
Reference should also be made to the ETCI rules for
electrical installation.
STANDARD
B.S. 6891
B.S. 5440: Pt 1
B.S. 5440: Pt 2
B.S. 5546
B.S. 7074
B.S. 5449
B.S. 6798
B.S. 7593
B.S. 7671
SCOPE
Gas Installation.
Flues.
Air Supply.
Installation of hot water supplies
for domestic purposes.
Expansion vessels and ancillary
equipment for sealed water systems.
Forced circulation hot water systems.
Installation of gas fired hot water
boilers.
Treatment of water in domestic hot
water central heating systems.
IEE Wiring Regulations
STANDARD
I.S. 813
B.S. 5546
B.S. 7074
B.S. 5449
B.S. 7593
SCOPE
Domestic Gas Installations.
Installation of hot water supplies
for domestic purposes.
Expansion vessels and ancillary
equipment for sealed water systems.
Forced circulation hot water systems.
Treatment of water in domestic hot
water central heating systems.
In IE:
The following BS standards give valuable additional information
In GB the following Codes of Practice apply:
© Baxi Heating UK Limited 2005

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© Baxi Heating UK Limited 2005
3.4 Electricity Supply
230V ~ 50Hz via a fused double pole switch with
a contact separation of at least 3 mm in both
poles.
There must be only one common isolator for the
boiler and its control system, it must provide
complete electrical isolation and be fitted
adjacent to the boiler.
There is no method of isolating the boiler at the
user interface.
The power cable to the boiler must be 4-core to
supply permanent live, neutral, earth and
switched live.
Electrical installation should be in accordance
with BS7671.
WARNING: THIS BOILER MUST BE EARTHED AND
CORRECTLY POLARISED.
3.5 Location of Boiler
The boiler must be mounted on a flat wall which
is sufficiently robust to take the weight of the
boiler.
Location
The boiler should be fitted within the building
unless otherwise protected by a suitable
enclosure.
Clearances
The boiler requires only the clearances shown
on Page 7, after installation.
Combustible Wall
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
25 mm annular space. Further guidance is
given in BS5440: Pt 1.
Timber Frame
If the boiler is to be fitted into a building of
timber frame construction then reference must
be made to the current edition of Institution of
Gas Engineers Publication IGE/UP/7/ (Gas
Installation in Timber Framed Housing).
Zone 2
Zone 1
Zone 0
Zone 2
Zone 3
Zone 3
Zone 2
Window
Recess
Window
Recess
0.6 m 2.4 m
In GB Only
Ceiling
Outside
Zones
Outside Zones
Zone 3
Zone 3
Zone 2
Zone 2
Zone 1
Zone 0
2.25 m
Zone 2
Window
Recess
3.0 m
2.4 m
0.6 m
In GB Only
Bath or Shower Room
If the boiler is fitted in a room containing a bath or shower, it
can only be fitted in Zone 3, Figs. 2 & 3 show Zone
dimensions for a bathtub. For other examples refer to
BS7671.
Cupboard or Compartment
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.
Service Access
Pipes and wiring must not restrict service access to
the boiler
Fig. 3

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3.6 Condensate Disposal
This boiler incorporates a 75 mm trap.
Ensure the disposal of condensate complies with
any national or local regulations in force.
Failure to install the condensate disposal pipework
correctly will affect the reliable operation of the
boiler.
The pipe must always slope continually downward
away from the boiler by at least 50 mm in every
metre (approx. 2.5°). No air breaks are required in
the pipe.
1. The pipe should be run in a proprietary drain pipe
material e.g. PVC, PVC-U, ABS, PVC-C or PP. Metal
pipework is NOT suitable for use in condensate
disposal systems.
2. The pipe should be a minimum of 21.5 mm diameter
and must be supported using suitably spaced clips
to prevent sagging.
3. To reduce the risk of condensate being trapped, as
few bends and fittings as possible should be used.
4. When disposing condensate into a soil stack or
waste pipe the effects of existing plumbing must be
considered. If soil pipes or waste pipes are subjected
to internal pressure fluctuations when WC's are
flushed or sinks emptied then back-pressure may
force water out of the boiler trap and could affect the
operation of the boiler.
5. Any condensate pipework external to the building (or
in an unheated part of it e.g. garage) should not
exceed 3 metres in length and when in an exposed
position, waterproof insulation is recommended. It is
also recommended that the pipe diameter is
increased to 32 mm.
If the boiler is fitted in an unheated location the entire
condensate pipe should be treated as an external
run.
Examples are shown of the following methods of
termination in order of preference:-
i) via an internal discharge branch
(e.g. sink waste) - Fig. 4.
ii) to an internal soil & vent pipe - Fig. 5.
iii) to a drain or gully - Fig. 6.
iv) to a purpose made soakaway - Fig. 7.
BS 6798 & Part H1 of the Building Regulations
give further guidance.
Boiler
50 mm per metre (2.5°)
Minimum fall
Termination to an internal soil
and vent pipe
450mm min
Boiler
Termination via internal discharge
branch e.g sink waste - downstream
Sink
Pipe must terminate
above water level but
below surrounding
surface
Boiler
Pipe must terminate
above water level but
below surrounding
surface
Termination to a drain or
gully
Boiler
500mm min
Termination to a purpose made
soak-away
Holes in the soak-away
must face away from the
building
Fig. 4
Fig. 5
Fig. 6
Fig. 7
© Baxi Heating UK Limited 2005