You can rely on Installation & Service Instructions Suprima HE Range Condensing Central Heating Boiler 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.
Contents 1. Introduction.....................................................4 2. Technical Data.................................................6 3. Installation Requirements..............................8 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 General Information........................................8 Legislation, Standards & Codes of Practice....8 Gas Supply......................................................8 Electricity Supply.............................................9 Location of Boiler.....
Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Self Certification Scheme Building Control Install and Commission this appliance to manufacturer's instructions Contact your relevant Local Authority Building Control (LABC) who will arrange an inspection or contact a government approved inspector Complete the Benchmark Checklist If you notify via the ‘Gas Safe Register’, the register will issue the Building Regulations certificate on members’ behalf
1. Introduction 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.
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.
2. Technical Data Models 30 HE 40 HE 50 HE 60 HE 70 HE 80 HE 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 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 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 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 mbar 8.6 10.4 9.0 8.4 11.4 12.8 in wg 3.44 4.
Return Connection Flow Connection Flow Sensor Overheat Sensor Casting Sensor Air Pressure Switch 'O' Ring and Clip Joints Fan and Flue Hood Secondary Heat Exchanger Primary Heat Exchanger Burner & Electrodes Data Label Wiring Centre PCB Enclosure Condensate Trap 75 mm Gas Connection 410 mm overall clearance Gas Valve Spark Igniter 125 mm clearance Condensate Connection 260 mm 15 mm clearance 850 mm 770 mm* overall clearance 595 mm 610 mm servicing clearance 400 mm 5 mm clearance 5 mm cleara
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.
3.4 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.
Boiler Termination via internal discharge branch e.g sink waste - downstream Pipe must terminate above water level but below surrounding surface Sink 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.
3.7 Air Supply 3.8 The room in which the boiler is installed does not require a purpose provided air vent. 3.7.1 Ventilated Cupboard/Compartment If the boiler is installed in a cupboard or compartment (with the exception of those installations covered by Section 3.7.2), permanent air vents are required in the cupboard or compartment, one at high level and one at low level, either direct to the outside air or to a room.
Terminal Position with Minimum Distance (Fig. 8) (mm) Aa Directly below an opening, air brick, opening windows, etc Ba Above an opening, air brick, opening window etc. Ca Horizontally to an opening, air brick, opening window etc. D Below gutters, soil pipes or drain pipes. E Below eaves. F Below balconies or car port roof. G From a vertical drain pipe or soil pipe. H From an internal or external corner. I Above ground, roof or balcony level. J From a surface or boundary line facing a terminal.
3.8.2 Horizontal Flue Systems 1. The standard flue is suitable only for horizontal applications. 2. Maximum permissible equivalent flue lengths is:Y X Horizontal Concentric 3.55m 3. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes: 135° bend 0.5 metres 93° bend 1.0 metres Twin Flue Pipe 135° bend 0.25 metres 91.5° bend 0.
Vertical Flues (Twin Pipe) 3.8.3 Twin & Vertical Flue Systems 1. Maximum permissible equivalent flue lengths are:Vertical Concentric Vertical Twin Pipe Y 1.9m 6m* * Both the air and flue duct can be up to 6 metres long each. X 2. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes: 135° bend 0.5 metres 93° bend 1.0 metres Twin Flue Pipe 135° bend 0.25 metres 91.5° bend 0.
3.8.
For Twin Flue Systems fit the adaptors as follows:- 3.8.5 Vertical Flue Boiler Adaptor Vertical Flue Duct Adaptor (Fig. 11) 1. Remove the flue elbow from top of the boiler and replace with the vertical flue duct adaptor ensuring the existing gasket is still in place. 3.8.6 Gasket Twin Vertical Flue Boiler Adaptor (Fig. 12) 1. Remove the flue elbow from top of the boiler and replace with the twin vertical flue duct adaptor ensuring the existing gasket is still in place. 2.
3.8.7 1. In the case of a pitched roof 25 - 50 degrees, position the lead tile to replace/flash over existing roof tiling. Make an aperture in the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained. The adjustable plastic collar can either be positioned on the lead tile or the lower tube of the roof terminal prior to the final positioning of the vertical flue through the tile.
93° Elbow/Plume Outlet Assembly 3.9 60Ø Support Bracket O Ring 0.9 metres Kit No 5118638 Content of kit 1 1 1 2 1 1 3 1 1 60Ø Exhaust Flue Pipe 60Ø Support Bracket O Ring Flexible Flue Trim Fig. 14a Plume Displacement Kit (Fig. 14b) Adaptor ‘Jubilee’ Clip 0.9m 60/100 Concentric Flue 1m 60 Dia Exhaust Flue Pipe Adaptor 60 Dia Support Brackets 93° Elbow/Plume Outlet Assembly Flexible Flue Trim “O” Rings ‘Jubilee Clip Boiler Elbow 1.
Graph Line F is suitable for Suprima 30, 40, 50, 60 HE Graph Line G is suitable for Suprima 70, 80 HE 20 16 14 12 G 10 F 18 60 Ø Exhaust (metres) 60 Ø Exhaust (metres) 3.9.1 20 F 18 16 In the graph the solid line diagonal represents the relationship between the concentric flue assembly (and any extensions) and the 60Ø exhaust (and any extensions or additional bends).
3.9.2 General Fitting Notes 1. Cut a hole in the external wall which the concentric flue assembly will pass through. The hole should allow the flue to fall back to the boiler at an angle of at least 1.5°. 2. When completed the terminal must be at least 2 metres above ground level (Fig. 19). Min. 2 metres 3. Measure and cut to size the concentric assembly and any extensions that are being used. 4. Insert the concentric assembly through the hole from outside the building. 5.
Plume Outlet Elbow 3.9.2 General Fitting Notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air. 16. It is also possible to separate the plume outlet from the 93° elbow to allow the flue to be installed as shown in Fig. 25. 50 0m m Mi n. 17. To do this, first slacken the two screws retaining the plume outlet to the elbow, and remove the outlet (Fig. 26).
3.10 Water Circulating Systems The boiler is suitable for use with fully pumped open vented and sealed systems with an indirect coil type high efficiency cylinder. The following conditions should be observed on all systems: • The static head must not exceed 30.5 m (100ft) (3 bar) of water or be less than 150 mm (6 in). • The flow pipe from the boiler must always be higher than the return pipe. • To ensure correct operation, the pump must be wired to the boiler terminal block. 3.10.
Boiler Protection 2 • A frost thermostat is fitted within the boiler controls which operates even if the temperature control knob is at the ( ) position. The boiler will operate as necessary to maintain the boiler temperature above freezing. • The boiler is fitted with a timed pump overrun that will operate for around 2 minutes after boiler shutdown. • The boiler control will operate the pump for around 2 minutes every 24 hours to maintain free running of the pump. 2.
3.10.6 Sealed Systems System Components All components used in the sealed system must be suitable for operation at 110°C and at the maximum pressure allowed by the pressure relief valve (normally 3 bar). Pressure Relief Valve A pressure relief valve, set to a maximum 3 bar opening pressure must be fitted. Pressure Relief Valve Discharge Pipe The pressure relief valve discharge pipe should be not less than 15mm diameter and run continuously downward.
Indirect HE Cylinder Auto air vent Pressure gauge visible from filling point Safety valve Optional 2 port valves Optional 3 port valve Pump with isolating valves Flow Automatic by-pass or existing by-pass balancing valve Expansion vessel Auto air vent Alternative existing by-pass arrangement using the bathroom radiator fitted with two lockshield valves 2m ** Return ** If plastic pipe is used for the central heating circuit there must be a run of at least 2 metres of uninsulated copper pipe from t
4. Installation Cut with 3° Rise MINIMUM CLEARANCE Centre Line Flow 4.1 MINIMUM CLEARANCE Unpack & Prepare the Wall & Boiler Core Drill Flue Hole 105mm (4")minimum Centre Line Return or 127mm (5") mimimum for Internal Fitment Kit These instructions assume you have chosen a suitable boiler location which will also allow correct installation of the condensate and flue systems.
4.2 Install the Flue These instructions are for standard horizontal rear and side flue applications which have a maximum horizontal installed length of 700 mm when fitted. Standard Horizontal Flue Minimum dimension X including wall thickness = 160 mm Rear flue Maximum dimension X = 700 mm The flue elbow is supplied set to the rear. For side outlet slacken the screws and turn the elbow to the required position and re-tighten screws. Ensure all flue elbow seals are still correctly located.
4.3 Schematic wiring with boiler interlock There must be both mains Permanent Live and Switched Live from the system to the boiler terminal block for the boiler protection devices to operate correctly. The pump must be wired to the boiler terminal block for the pump overrun to operate correctly. Mains N Ensure that the length of the earth wires are such, that if the supply cables are pulled out of the cable clamps the live and neutral wires become taut before the earth wire.
4.4 Connect the Gas Supply 1. Ensure that the gas supply is isolated at the meter. 2. Solder the gas tail (supplied) to main gas supply before connecting the tail to the gas cock. Gas cock Open Securing screws To prevent blow lamp damage to the wiring and condensate trap, any soldering of gas pipework must be done away from the boiler. Do not turn the gas supply on until soundness test and boiler installation are complete. 4.5 Remove 'O' Ring from gas cock before soldering pipework Fig.
b 30 or b b - blue bk - black br - brown g/y - green/yellow or - orange p - purple y - yellow r - red w - white Casting Thermistor Air Pressure Switch or y Flow Thermistor y Gas Valve bk r b br Spark Electrode Spark Generator bk bk bk Overheat Stat g/y Fan p p w Flame Detection Electrode br r y b g/y g/y Mains Pump L N E SwL L N E b g/y g/y g/y Earth to Burner 5. Wiring Diagrams Boiler Wiring Fig.
© Baxi Heating UK Ltd 2010 g/y br Fused 3A Mains Supply b Typical wiring centre 12 way shown Frost stat b - blue br - brown g/y - green yellow N E SwL L N E N L 4 4 3 E 5 5 C 6 6 N 7 7 Room stat NC Mid position valve 2 1 g/y br b Pump Mains This Appliance must be Ear thed L 8 9 10 11 12 Optional external programmer 8 10 11 12 Cyl stat NC NO C 9 Pump supplied from boiler L N E CH on HW on HW off b CH Zone valve Typical wiring centre 12 way shown Frost stat
6. Commissioning 6.1 Commission the Water, Electrical and Gas Systems 9. Turn the temperature control knob to ( ) position and check that the burner shuts down. Water The system should be cold flushed. After re-filling, all air must be vented from the system before the boiler is commissioned. On Sealed Systems, manually test the safety valve and fill until the pressure gauge registers 1.5 bar. 10. Remove the pressure gauge, re-fit the screws and check for gas soundness.
6.4 Final Adjustments Temperature Control Turn the temperature control knob to adjust the radiator surface temperature and hot water tap temperature between approximately 63°C and 82°C. Overheat Thermostat The boiler will require re-setting if an overheat condition occurs (the ‘Lockout’ (Red) light will flash). Other Boiler Controls No further setting or checking is necessary as all boiler mounted controls are fail safe.
7.
8.
Electrical Supply Fault Refer to the boiler wiring diagram Lockout Burner off off Mains off This boiler requires both a permanent live and a switched live.
Ignition Lockout Lockout Burner Mains off on Refer to the boiler wiring diagram on Is more than 17 mbar dynamic pressure at the gas valve inlet ? No Incorrect gas supply to boiler Yes Are Live and Neutral to boiler reversed ? Yes Correct the Live and Neutral connections Replace PCB Replace gas valve No Using meter test dial, does gas flow during ignition sequence ? Yes Yes No Is there 200 VDC at the gas valve during ignition sequence ? Check the continuity of the gas valve lead No Rectif
Overheat Lockout Lockout Burner Mains flashing off Lockout Burner Mains flashing flashing Refer to the boiler wiring diagram Wait until the temperature at the flow pipe is <60C Unplug the 8 way connector from PCB. Is there continuity between the 2 black wires ? on Yes Check as the 'Water Circulation Lockout' fault No Remove connectors from overheat thermostat.
Water Circulation Lockout Lockout Refer to the boiler wiring diagram Burner Mains This indication can be activated by two faults: on flashing flashing 1) Flow direction is checked after 1 minute of burner fire. If the casting thermistor reads a higher temperature than the flow thermistor, the fault occurs. This does not cause a lockout. 2) Adequate circulation is checked continuously during burner fire. If the casting thermistor exceeds 80C the fault occurs.
Air Pressure Switch Stuck Fault Lockout Refer to the boiler wiring diagram flashing Switch the boiler on Yes After 15 seconds, does the fan run No Unplug the 12 way connector from PCB. Is there continuity between the 2 orange wires No Refit the 12 way connector to PCB. Unplug one APS lead Switch boiler on. Does fan run ? Unplug the APS leads Is there continuity across the the APS Mains off off Replace PCB No Open circuit on the wiring.
Thermistor Fault - Flow and Casting Refer to the boiler wiring diagram Lockout There are two types of fault which can occur: on 1) The thermistors are reading outside of limits (this is checked before the PUMP is switched on and during Burner on). 2) The difference between the thermistor readings are outside of limits (this is checked during PUMP on stage). Check that the Pump is running and there is adequate circulation of water.
9. Servicing • For reasons of safety and economy the boiler should be serviced annually by a competent person. • Any 'O' rings, seals or gaskets disturbed during servicing or replacement of parts must be visually inspected and replaced if worn or damaged. • Important: Always test for gas soundness after servicing or replacement of gas carrying components and carry out functional checks of controls.
Flow Connection Return Connection Flow Sensor Overheat Sensor Flue Sample Point Casting Sensor Air Pressure Switch 'O' Ring and Clip Joints Fan and Flue Hood Secondary Heat Exchanger Primary Heat Exchanger Burner & Electrodes Data Label Wiring Centre PCB Enclosure Condensate Trap Gas Connection Spark Igniter Gas Valve Condensate Connection Fig.
9. Parts Replacement 9.2 General Access 1. Isolate the supplies as detailed in 9.1.2. 2. Pull the door panel down and remove the two screws. Carefully slide the bottom cover out and away from the boiler. 3. Remove the three screws and carefully lift the outer case away from the boiler. 9.3 PCB Enclosure Disconnect electrical plugs 9.3 1. Perform General Access - See 9.2. Removal of the outer case is not necessary. 2. Disconnect all electrical plugs and slide the enclosure out of its frame. Fig. 51 3.
9.5 Air Pressure Switch Ease bracket open 1. Perform General Access - See 9.2. Disconnect tubes 2. Disconnect the wires at the switch. 3. Note how they are fitted then disconnect the sensing tubes at the switch. 4. Ease the front of the bracket forwards and carefully prise the switch out of the bracket. If the bracket is removed for any reason, note that the hole in the side face locates around a rivet head. 5. Re-assemble in reverse order, polarity is not important when connecting the wires.
9.9 Fan and Flue Hood Warning 325V d.c a.c fan - 30 to 60 models d.c. fan - 70 and 80 models Isolate the mains supply. 1. Perform General Access - See 9.2. Sensing tubes 2. Remove the screw securing the front combustion chamber cover. Pull the cover out slightly then down to unhook and lift away from the boiler. Fan motor 9 - 18 shown 3. Note how they are fitted then disconnect the sensing tubes from the venturi. 4.
9.10 Electrodes/Burner 1. Perform General Access - See 9.2. 2. Remove the combustion chamber cover See 9.9. Sensing electrode Ignition electrode Remove screw 3. Disconnect the ignition lead from the ignition electrode and the sensing lead and earth lead from the sensing electrode. If replacing electrode(s), remove securing screw(s) as appropriate. 4.
9.12 Combustion Chamber Insulation Important: See Section 3.1, Health and Safety information before handling insulation. 1. Perform General Access - See 9.2. 2. Remove the screw securing the front combustion chamber cover. Pull the cover out slightly then down to unhook and lift away from the boiler. 9.12 Location lip 3. Remove the Burner - See 9.10. 4. Remove the two screws securing the side and rear insulation assembly to the front of the chassis. 5. Pull the assembly forwards and away from the boiler.
9.13 Condensate Trap 1. Perform General Access - See 9.2. Place a vessel underneath to catch the condensate then remove the drain plug. Take care as the condensate could be hot. Spring clip 2. Disconnect condensate disposal pipework from the flat faced union on the trap and swing pipework away from boiler. 3. Release the spring clip securing the rubber tube to the base of the sump. Right hand screw 4. Loosen the left hand and remove the right hand screw securing the trap to the boiler. 5.
9.14 Primary Heat Exchanger Screw 1. Perform General Access - See 9.2. Flue duct securing bracket 2. Drain the system as necessary. 3. Remove the combustion chamber cover See 9.9. Bolt Screw Nut 4. Drain the heat exchanger, a drain point is located on the left hand side bottom of the heat exchanger. Attach a tube to the drain point, turn anti-clockwise to open and drain water away from the electronics. 5. Remove the Casting Sensor - See 9.7. 6. Remove the Fan and Flue Hood - See 9.9. 9.14 Fig.
9.15 Secondary Heat Exchanger 1. Perform General Access - See 9.2. 2. Drain the system as necessary. 3. Drain the Heat Exchanger - See 9.14, 4. Pipe clips 4. Remove the Spark Igniter - See 9.6. To ease removal of the secondary heat exchanger it may be necessary to:- Remove the Air Pressure Switch - See 9.5. Remove the air pressure switch mounting bracket. Remove the Fan and Flue Hood - See 9.9. Disconnect secondary to primary heat exchanger return pipe. 9.15 5.
10. Short Spares 216 [60 to 80HE] 217 308 329 330 216 [30 to 50HE] 306 332 207 331 322 206 [60 to 80HE] 121 318 120 209 206 [30 to 50HE] 219 313 200 [70 to 80HE] 305 200 [30 to 60HE] 202 Fig.
Drg. Ref. G.C. No. Description Qty Part No.
GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing controls.
All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet. All goods are sold subject to our standard Conditions of Sale which are available on request. P O T T E RTO N A Tr a d i n g D i v i s i o n o f B a x i H e a t i n g U K L t d ( 3 8 7 9 1 5 6 ) A Division of Baxi Group Brooks House, Coventry Road, Warwick.
