Potterton Suprima 30 Manual de usuario

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

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

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)

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

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

Pump

Speed

Pump

Speed

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

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

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

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

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

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

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

ENL

1 72 83 94

5 6

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

CH on

Com

Power Consumption:

150W - Boiler (approx)

5W - M.P.V. (approx)

112W - Pump (maximum)H

Optional

Programmer

PumpMains

This Appliance must be Earthed

Programmer

Wiring

Terminal

Connector (7 way)

Suprima Boiler

Optional

Programmer

Connector

(3 way)

L LE ESwL

out

DHW

off

out

Fig. 10

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