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Potterton Eurocondense five 125 kW Installation Manual

Gas condensing boiler
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Installation Manual
Gas condensing boiler
Eurocondense five 125 kW
Eurocondense five 170 kW
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Eurocondense five 260 kW
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Summary of Contents for Potterton Eurocondense five 125 kW

  • Page 1 Installation Manual Gas condensing boiler Eurocondense five 125 kW Eurocondense five 170 kW Eurocondense five 215 kW Eurocondense five 260 kW Eurocondense five 300 kW...
  • Page 2 Dear Customer, Thank you very much for buying this appliance. Please read through the manual carefully before using the product, and keep it in a safe place for later reference. In order to ensure continued safe and efficient operation we recommend that the product is serviced regularly. Our service and customer service organisation can assist with this.

  • Page 3: Table Of Contents

    Use of antifreeze agents with Potterton heat generators ....... . .
  • Page 4 Contents 5.11.1 Application example ..............35 5.11.2 Legend .
  • Page 5 Contents Settings ..................60 List of parameters .
  • Page 6 Contents 12.1.1 Decommissioning the domestic water storage tank ......... . 150 12.1.2 Draining off the heating water .

  • Page 7: Safety

    1 Safety Safety General safety instructions Danger If you smell gas: 1. Do not use a naked flame, do not smoke, do not operate electrical contacts or switches (doorbell, light, motor, lift, etc.). 2. Shut off the gas supply. 3. Open the windows. 4.
  • Page 8 1 Safety Danger Risk of poisoning. Never use condensate water as drinking water! Condensate is not suitable for consumption by people or animals. Do not let the skin come into contact with condensate. Suitable protective clothing must be worn during maintenance work.

  • Page 9: Intended Use

    1 Safety Danger Replacement of damaged parts may only be performed by an installer. Warning Risk of damage! The condensing boiler may only be installed in rooms with clean combustion air. Foreign matter such as pollen must never filter through the inlet apertures to reach the inside of the appliance.

  • Page 10: Liabilities

    1 Safety Liabilities 1.3.1 Manufacturer's liability Our products are manufactured in compliance with the requirements of the various Directives applicable. They are therefore delivered with the marking and any documents necessary. In the interests of the quality of our products, we strive constantly to improve them. We therefore reserve the right to modify the specifications given in this document.

  • Page 11: Specific Safety Instructions

    1 Safety Specific safety instructions 1.4.1 Liquid gas below ground level The EC five complies with DIN EN 126 and DIN EN 298 and, therefore does not need an additional disconnector valve for operation with liquid gas below ground level. 7703301 - 01 - 16072018...

  • Page 12: About This Manual

    2 About this manual About this manual General This manual is intended for the installer of a EC five boiler. Additional documentation Here is an overview of the further documents belonging to this heating system. Tab.1 Overview table Documentation Contents Intended for Technical information Planning documents...
  • Page 13 2 About this manual Important Please note: important information. Reference to other manuals or pages in this manual. 7703301 - 01 - 16072018...

  • Page 14: Technical Specifications

    3 Technical specifications Technical specifications Homologations 3.1.1 Regulations and standards Beside the general technical rules, the relevant standards, regulations, ordinances and guidelines should be followed: DIN 4109: Sound insulation in buildings DIN EN 12828: Heating systems in buildings –, planning domestic hot water heating systems Federal Immission Control Ordinance 1.

  • Page 15: Technical Data

    3 Technical specifications Technical data 3.2.1 Technical data – Boiler space heaters in accordance with ErP guideline Tab.2 Technical data for boiler space heaters in accordance with ErP guideline Product name EC five EC five EC five EC five EC five 125 kW 170 kW 215 kW...
  • Page 16 3 Technical specifications Model EC five EC five EC five EC five EC five 125 kW 170 kW 215 kW 260 kW 300 kW Nominal heat input range Natural gas Heating kW 20.0-125.0 28.0-170.0 35.0-215.0 42.0-260.0 48.0-300.0 Heating kW 35.0-125.0 35.0-170.0 48.0-215.0 58.0-260.0...

  • Page 17: Technical Data For The Auxiliary Contactor For The Pump Phs

    3 Technical specifications Model EC five EC five EC five EC five EC five 125 kW 170 kW 215 kW 260 kW 300 kW Volume flow ∆T = 20 K kg/h 5375 7310 9245 11180 12900 ∆T = 10 K kg/h 10750 14620...

  • Page 18: Pressure Drop Secondary Circuit

    3 Technical specifications Temperature [°C] Resistance [Ω] 15699 12488 10000 8059 6535 5330 4372 3605 2989 2490 2084 1753 1481 1256 1070 3.2.5 Pressure drop secondary circuit Fig.1 Pressure drop secondary circuit RA-0000209 WMS [m Pressure drop secondary circuit Water mass flow EC five 125 kW EC five 170 kW EC five 215 kW...

  • Page 19: Dimensions And Connections

    3 Technical specifications 3.2.6 Dimensions and connections Fig.2 Dimensions and connections RA-0000208 Tab.5 Dimensions Model EC five EC five EC five EC five EC five 125 kW 170 kW 215 kW 260 kW 300 kW Air supply duct Ø 110 Ø...
  • Page 20 3 Technical specifications Model EC five EC five EC five EC five EC five 125 kW 170 kW 215 kW 260 kW 300 kW Dimension A Dimension B 1008 1008 1171 1264 1357 Dimension C Dimension D Dimension E Dimension F Dimension G 1037 Dimension H...

  • Page 21: Wiring Diagram

    3 Technical specifications 3.2.7 Wiring diagram Fig.3 Wiring diagram RA-0001306 ATF Outdoor temperature sensor QAC 34 GW Gas pressure monitor B1 Ionisation electrode H1,4,5 Multifunctional Input *) BE Operating unit H6 Gas pressure Monitor input Bus BE Bus connection for operating unit HP Heating circuit pump *) Bus EM Bus connection for expansion module KRF Boiler return sensor type 36...
  • Page 22 3 Technical specifications M4 Burner fan TLP Domestic water charging pump *) mains Mains Connection 230V/50Hz TWF DHW sensor type 36 P1 PWM output TZP Domestic water circulation pump *) QX1...3 Multifunctional output X11,60 Bus module interface S1 Operating switch X12,13 Service interfaces S2 Unlocking Y2 Gas solenoid valve...

  • Page 23: Description Of The Product

    4 Description of the product Description of the product Operating principle 4.1.1 Description of the function of the air pressure monitor Fig.4 Connection of the air pressure Air pressure monitor monitor (schematic) Venturi During pre-purge, the air pressure switch (differential pressure switch) is interrogated.

  • Page 24: Control Panel Description

    4 Description of the product Fig.6 Boiler view EC five 215 kW - 300 1 Flue gas connection 2 Boiler flow (KV) 3 Safety group connection 4 Boiler return (KR) 5 Air supply duct 6 Gas connection 7 Boiler control LMS 8 Ignition transformer (below the control unit) 9 Ionization electrode 10 Flame inspection window (below the control unit)

  • Page 25: Displays

    4 Description of the product 4.3.2 Displays Fig.8 Symbols on the display Heating to comfort setpoint Heating to reduced setpoint Heating to frost protection setpoint Current process Holiday function active Reference to heating circuits Burner in operation (boiler only) Cooling active (heat pump only) Compressor in operation (heat pump only) Maintenance message Fault message...

  • Page 26: Before Installation

    EC five must be kept free at all times. Treating and preparing the heating water 5.4.1 Introduction This section explains the conditions for heating water when Potterton condensing boilers are used. Important Please note that the boiler EC five has an aluminium silicon heat exchanger.

  • Page 27: Heating Water Requirements

    Heating systems in which a Potterton condensing boiler is to be installed must be designed as a closed heating system with diaphragm expansion vessel in accordance with DIN EN 12828.

  • Page 28: Addition Of A Product To Treat The Heating Water

    (dispersion) and form a corrosion protection layer on metallic surfaces. Only products approved by Potterton may be used to treat heating water. Softening/desalination may only be carried out using appliances approved by Potterton, while taking the limit values into consideration.

  • Page 29: Full Desalination/Partial Desalination

    5 Before installation Important A softening system reduces calcium and magnesium to prevent the formation of scale (VDI directive 2035 Sheet 1). No corrosive water components are reduced or removed (VDI directive 2035 Sheet 2). Tab.6 Table to VDI 2035 Sheet 1 Total heating output in kW Total hardness in °dH depending on the specific system volume <...

  • Page 30: Maintenance

    (= fill water volume) plus the top-up water volume. In the 1000 Potterton boiler-specific diagrams only the system volume is given to make them easier to read. Over the entire service life of the boiler, a maximum top-up volume of twice the system volume is assumed.
  • Page 31 Potterton in relation to its practical suitability for use with condensing boilers. Important Up to a mixing ratio of 2:1, the heat transfer fluid WTF B is approved as frost protection down to -15 °C for use with Potterton condensing boilers. Caution Keep the installation room frost-free.

  • Page 32: Choice Of The Location

    5 Before installation Choice of the location 5.9.1 Notes for installation location Caution Install the boiler on a solid, stable structure able to bear its weight. Caution Danger of damage from water! The following must be observed when installing the EC five: In order to prevent damage due to water, particularly due to leakages in the DHW storage tank, suitable precautionary measures should be taken regarding installation.

  • Page 33: Space Requirement

    5 Before installation 5.9.2 Space requirement Fig.10 Recommended space requirement EC five EC five EC five EC five EC five 125 kW 170 kW 215 kW 260 kW 300 kW Dimension 60 cm 70 cm 80 cm 90 cm 100 cm Dimension 50 cm Dimension...

  • Page 34: Unpacking

    5 Before installation 5.10.2 Unpacking Caution Sharp-edged packaging material Risk of cuts on the sharp-edged cardboard packaging Wear gloves when unpacking the unit. Danger Risk of asphyxiation! The unit's packaging material (e.g. plastic film) presents a risk of asphyxiation for children. Never allow children to play with packaging material.

  • Page 35: Connecting Diagrams And Configuration

    With pipe separation according to DIN 1717 Important The AguaSave and AguaClean modules are optional accessories for conditioning heating water in accordance with VDI 2035 and the specific requirements of Potterton Important The circulating pump must be actuated on-site or via an additional B EWM.
  • Page 36 5 Before installation Fig.13 EC five, one pump heating circuit and hot water preparation, AguaSave and AguaClean optional (connecting diagram) RA-07996-B02 Important The maximum current is 1 ampere per output and 5 amperes per controller. If consumers exceed 1 ampere or 5 amperes, pump contactor relays (PHS) should be used.

  • Page 37: Legend

    5 Before installation 5.11.2 Legend Tab.9 Sensor names Name in the hydraulic Name in the control system Function/explanation Type system Outdoor temperature sensor B9 Measures the outside temperature QAC34 DHW sensor B3 Measures the upper domestic hot water tempera­ Z 36 ture Type D is a surface-contact sensor, type Z is an immersion sensor, the collector sensor has a black silicone cable and the sensors for the SOR S/M are Pt1000 sensors.

  • Page 38: Installation

    6 Installation Installation General Warning Risk of injury! Objects (e.g. tools) that are carelessly placed on the unit lead to a risk of injuries and damage. Do not place any objects on the unit. Even for a short time! Assembly 6.2.1 Converting the exhaust connection The conversion of the top passage to the side or rear passage of the flue...

  • Page 39: Installing The Air Supply Duct At The Side

    6 Installation 6.2.2 Installing the air supply duct at the side The installation of the air supply duct on the left-hand side of the boiler is shown below. 1. Remove the lower rear wall 2. Remove the side cover plate 3.

  • Page 40: Hydraulic Connections

    EC five must be inserted through the opening in the rear or side wall. If there is no run-off facility underneath the condensate discharge, the use of the Potterton neutralisation and lifting system is recommended. Important Danger to life due to flue gas escaping! Fill the condensate discharge with water before commissioning.

  • Page 41: Check Tightness

    Important Connecting the boiler as RLUA-version (RLUA-set and possibly WAS) may give rise to reduced output of the boiler, which is compensated by Potterton customer service. Approval number The SAS has been approved by the Deutsche Institut für Bautechnik (DIBt) (German Institute for Civil Engineering) in general conformance with building regulations: Approval Number Z-7.2.-1104...

  • Page 42: Flue Gas System

    For more elbows, the following deductions have to be made 1 elbow 87°: 5 m 1 elbow 45°: 2 m 1 elbow 15°: 1 m A calculation by Potterton is required for individual cases of room air- independent operation of the EC five. 7703301 - 01 - 16072018...

  • Page 43: General Information About The Flue Gas Piping System

    A table of permissible flue gas pipe lengths for cascade systems Technical information . A calculation by can be found in the Potterton is required for installations deriving from this. 6.5.3 General information about the flue gas piping system Caution Risk of property damage! The chosen flue gas path should be as short as possible.

  • Page 44: Chimneys Already In Use

    6 Installation Lightning protection Danger of electric shock Danger to life due to lightning strike. The chimney head cover must be integrated in any existing lightning protection system and house-side potential equalisation. This work should be carried out by an approved company specializing in lightning protection and electrical work.
  • Page 45 6 Installation Minimum dimensions of the duct Fig.15 Minimum dimensions of the duct Outer Ø cou­ Min. duct inner dimension pling short side A round B System [mm] [mm] [mm] SAS 160 (DN 160) SAS 200 (DN 200) Back ventilation For room air-depending operation of the gas condensing boiler with the SAS 160 and SAS 200 the duct below the flue gas connection in the RA-0000159...

  • Page 46: Cleaning And Inspection Openings

    6 Installation 6.5.6 Cleaning and inspection openings Danger Clean exhaust gas pipelines! It should be possible to clean the flue gas pipes and inspect their free cross-section and leakproofness. At least one cleaning and inspection opening must be installed in the installation room of the EC five.

  • Page 47: Cable Lengths

    6 Installation Danger of electric shock Danger to life! Risk of injury or a risk to life from electric shock! The use of rigid lines (e.g. NYM) is not allowed because of the risk of cable damages! There are only to use flexible cables, e.g H05VV-F for high voltage power cables, and e.g.

  • Page 48: Replacing Cables

    6.6.7 Replacing cables All connecting cables, except for the mains connection cable, have to be replaced by Potterton special cables in case of replacement. When replacing the mains connection cable, only cables of the types H05VV-F 3 x 1 mm or 3 x 1,5 mm have to be used.

  • Page 49: Filling The System

    6 Installation Fig.21 Opening the terminal strip contacts Insert a screwdriver into the terminal strip as shown and lever it open Insert the connection cables into the terminal contacts and remove the screwdriver RA-0000296 Filling the system 1. Fill the heating system using the boiler fill and drain valve (BFD valve) of the EC five 2.

  • Page 50: Commissioning

    7 Commissioning Commissioning General Danger Commissioning may only be carried out by an approved installer. The installer checks the tightness of pipes, the correct function of all regulating, control and safety equipment, and measures the combustion values. If this work is not carried out correctly, there is a risk of considerable damage to persons, environment and property.

  • Page 51: Commissioning Procedure

    7 Commissioning Commissioning procedure 7.3.1 Commissioning menu The commissioning menu will be shown once during initial commissioning. 1. Select Language and confirm with OK-Taste. 2. Selcet Year and confirm. 3. Set Time of day and date and confirm. 4. Conclude by pressing the OK-Taste. Important If the commissioning menu entry is terminated by pressing ESC- RA-0000065...

  • Page 52: Manual Adjustment Of Burner Output (Controller Stop Function)

    7 Commissioning EC five EC five EC five 125 kW 170 kW 215 kW Function Prog. no. Setting level Natural Propane Natural Propane Natural Propane Boiler Output basic stage 2331 Burner control Required output prepurging 9504 Required output ignition 9512 59.3 66.3 75.5...

  • Page 53: Adjusting Co Content

    7 Commissioning 7.4.5 Adjusting CO content Fig.22 Overview of gas valve Compensation line Adjustment screw for small load (Torx TX 40) Adjustment screw for full load (Allen key 3 mm) Gas pressure monitor Measuring nozzle for inlet pressure RA-0000225 Setting CO content at max.

  • Page 54: Documents

    7 Commissioning The supply air opening must not be closed or restricted The connection nozzle for the combustion air at the top of the device must be accessible for the chimney sweep The following control checks himself that he has to perform himself: Pressure check on the manometer Check of the receiver under the blowpipe of the safety valve Only an approved heating specialist may carry out the inspection and...

  • Page 55: Operation

    8 Operation Operation Use of the control panel 8.1.1 Changing parameters Settings which are not directly changed via the operating panel must be carried out on the setting level. The basic programming process is depicted in the following using the example of the setting of Time of day and date.

  • Page 56: Programming Procedure

    8 Operation 8.1.2 Programming procedure The selection of the setting levels and menu items is done as follows: 1. Press OK. End user level are displayed. The menu items under the 2. Press information button for approx. 3 s. The setting levels appear. 3.

  • Page 57: Setting Necessary Parameters

    8 Operation 5. Use the operating mode key for heating mode to select the automatic operating mode on the boiler control unit xxxxxxxxxxxxxx RA-0000163 6. Set the required room temperature using the control of the control unit RA-0000164 8.2.3 Setting necessary parameters Normally, the parameters of the regulator do not need to be modified.

  • Page 58: Adjusting Domestic Water Mode

    8 Operation 8.2.5 Adjusting domestic water mode Switched on Domestic water is prepared according to the selected switching programme. Switched off Domestic water preparation has been de-activated. XXXXXXXXXXXXXX XXXX Important A setting between 50 and 60°C is recommended for domestic water heating.

  • Page 59: Chimney Sweep Function

    8 Operation 3. Adjust nominal value by using rotating knob 4. Acknowledge setting with OK. 8.2.9 Chimney sweep function The chimney sweep function is activated or deactivated using the Chimney-sweep button. 1. Press the Chimney-sweep button The activated special function is displayed by the symbol in the display.

  • Page 60: Settings

    9 Settings Settings List of parameters Subject to system configuration, not all parameters listed in the parameter list will be shown on the display. To reach the end user (Eu), Commissioning (C) and Engineer (E) setting levels: 1. Press the OK button. 2.
  • Page 61 9 Settings Wireless Prog. no. Level Standard value Room unit 1 Missing Missing | In operation | No recept'n | Change batt Room unit 2 Missing Missing | In operation| No recept'n | Change batt Room unit 3 Missing Missing | In operation | No recept'nChange batt Outside sensor Missing Missing | In operation| No recept'n | Change batt...
  • Page 62 9 Settings Time program 5 Prog. no. Level Standard value 1st phase off 22:00 (h/min) 2nd phase on --:-- (h/min) 2nd phase off --:-- (h/min) 3rd phase on --:-- (h/min) 3rd phase off --:-- (h/min) Copy? Default values No | Yes Holiday Heating Heating...
  • Page 63 9 Settings Heating circuit Level Standard value Prog. no. Prog. no. Prog. no. Floor curing function 1150 1450 0: Off 0: Off | 1: Functional heating | 2: Curing heating | 3: Functional/curing heating | 4: Curing/functional heating | 5: Manually Floor curing setp manually 1151 1451...
  • Page 64 9 Settings Prog. no. Level Standard value Circulation setpoint 1663 55 °C Optg mode changeover 1680 1: Off 0: None | 1: Off | 2: On Consumer circuit / swimming pool circuit Consumer Consumer Swimming Level Standard value circuit 1 circuit 2 pool circuit Prog.
  • Page 65 9 Settings Boiler Prog. no. Level Standard value Pump modulation 2320 3: Temp differential 0: None | 1: Demand | 2: Boiler setpoint | 3: Temp differential nominal | 4: nominal Burner output Pump speed min 2322 Pump speed max 2323 100% Output nominal...
  • Page 66 9 Settings Boiler Prog. no. Level Standard value 2452 EC five 125 kW: 20 Controller delay fan output EC five 170 kW: 28 EC five 215 kW: 35 EC five 260 kW: 42 EC five 300 kW: 48 Controller delay duration 2453 60 s Switching diff on HCs...
  • Page 67 9 Settings Solar Prog. no. Level Standard value Charging time relative prio 3825 - - - min Waiting time relative prio 3826 5 min Waiting time parallel op 3827 - - - min Delay secondary pump 3828 60 s Collector start function 3830 - - - min Min run time collector pump...
  • Page 68 9 Settings Buffer storage tank Prog. no. Level Standard value Full charging temp min 4811 8 °C Full charging sensor 4813 2: With B42/B41 1: With B4 | 2: With B42/B41 Prog. no. Level Standard value DHW storage tank Forward shift charging 5011 01:00 (h:min) Flow setpoint boost...
  • Page 69 9 Settings DHW storage tank Prog. no. Level Standard value Min start temp diff Q33 5148 -3 °C Excess interm circ temp del 5151 30 s (1) Parameters depend on the hydraulic System! Configuration Prog. no. Level Standard value Heating circuit 1 5710 1: On 0: Off | 1: On...
  • Page 70 9 Settings Configuration Prog. no. Level Standard value Sensor input BX2 5931 1: DHW sensor B31 Parameters see Sensor input BX1 (prog. no. 5930)! Sensor input BX3 5932 5: Buffer sensor B4 Parameters see Sensor input BX1 (prog. no. 5930)! Function input H1 5950 0: None...
  • Page 71 9 Settings Configuration Prog. no. Level Standard value Signal logic output P1 6086 1: Inverted 0: Standard | 1: Inverted Sensor type collector 6097 1: NTC 1: NTC | 2: Pt 1000 Readjustm collector sensor 6098 0 °C Readjustm outside sensor 6100 0 °C Time constant building...
  • Page 72 9 Settings Modbus Prog. no. Level Standard value Slave address 6651 - - - Baud rate 6652 4: 19'200 0: 1'200 | 1: 2'400 | 2: 4'800 | 3:9'600 | 4: 19'200 Parity 6653 0: Even 0: Even | 1: Odd | 2: None Stop bit 6654 Error...
  • Page 73 9 Settings Service/special operation Prog. no. Level Standard value Chimney sweep function 7130 Off | On Manual control 7140 Off | On Controller stop function 7143 0: Off 0: Off | 1: On Controller stop setpoint 7145 100 % Forced heat draw DHW 7165 0: Off 0: Off | 1: On...
  • Page 74 9 Settings Config extension module Prog. no. Level Standard value Function input H2/H21 module 1 7321 0:None 0:None | 1: Optg mode change HCs+DHW | 2: Optg mode changeover DHW | 3: Optg mode changeover HCs | 4: Optg mode changeover HC1 | 5: Optg mode changeover HC2 | 6: Optg mode changeover HC3 | 7: Heat generation lock | 8: Error/alarm message | 9: Consumer request VK1 | 10: Consumer request VK2 | 11: Release swi pool source heat | 12: Excess heat discharge | 13: Release swi...
  • Page 75 9 Settings Config extension module Prog. no. Level Standard value Sensor input BX21 module 2 7382 0: None Parameters see Sensor input BX21 module 1 (prog. no. 7307)! Sensor input BX22 module 2 7383 0: None Parameters see Sensor input BX21 module 1 (prog. no. 7307)! Function input H2/H21 module 2 7396 0: None...
  • Page 76 9 Settings Config extension module Prog. no. Level Standard value Sensor input BX22 module 3 7458 0: None Parameters see Sensor input BX21 module 1 (prog. no. 7307)! Function input H2/H21 module 3 7471 0: None Parameters see Function input H2/H21 module 1 (prog. no. 7321)! Contact type H2/H21 module 3 7472...
  • Page 77 9 Settings Input/output test Prog. no. Level Standard value Output test UX21 module 3 7788 Output signal UX21 module 3 7789 Output test UX22 module 3 7790 Output signal UX22 module 3 7791 Sensor temp BX1 7820 Sensor temp BX2 7821 Sensor temp BX3 7822...
  • Page 78 9 Settings Diagnostics cascade Prog. no. Level Standard value Priority/state source 1 8100 0: Missing | 1: Faulty | 2: Manual control active | 3: Heat generation lock active | 4: Chimney sweep funct active | 5: Temporarily unavailable | 6: Outside temp limit active | 7: Not released | 8: Released Priority/state source 2 8102...
  • Page 79 9 Settings Diagnostics heat generation Prog. no. Level Standard value Collector pump 1 8499 0: Off | 1: On Solar ctrl elem buffer 8501 0: Off | 1: On Solar ctrl elem swi pool 8502 0: Off | 1: On Speed collector pump 1 8505 Speed solar pump ext exch...
  • Page 80 9 Settings Diagnostics consumers Prog. no. Level Standard value Flow temp 2 8773 Flow temp setpoint 2 Room thermostat 2 8779 0: No demand | 1: Demand Heating circuit pump 3 8790 0: Off | 1: On HC mixing valve 3 open 8791 0: Off | 1: On HC mixing valve 3 closed...
  • Page 81 9 Settings Diagnostics consumers Prog. no. Level Standard value Relay output QX21 module 2 9053 0: Off | 1: On Relay output QX22 module 2 9054 0: Off | 1: On Relay output QX23 module 2 9055 0: Off | 1: On Relay output QX21 module 3 9056 0: Off | 1: On...
  • Page 82 9 Settings Prog. no. Level Standard value Fan output/speed slope 9626 EC five 125 kW: 37.1 EC five 170 kW: 27.6 EC five 215 kW: 26.4 EC five 260 kW: 20.1 EC five 300 kW: 19.9 Fan output/speed Y-section 9627 EC five 125 kW: 501.1 EC five 170 kW:...

  • Page 83: Description Of The Parameters

    9 Settings Description of the parameters 9.2.1 Time and date Time and date (1–3) The regulator has a year clock with setting possibilities for time, day/month and year. Time and date must be correctly set, so that the heating programs can operate to previously carried out programming. Summer time (5/6) The start of summer time can be set under prog.

  • Page 84: Wireless

    9 Settings Caution The control parameters are overwritten. The factory settings are stored in the operating unit. operating unit . Activation of prog. no. 31 at the The regulator is reset to factory setting. room unit : Activation of prog. no. 31 at the The individual programming of the room unit is written into the control.

  • Page 85: Time Programs

    9 Settings Delete all devices (140) The wireless connections to all units is cancelled here. 9.2.4 Time programs General information about the time programs. Important Time programs 1 and 2 are always assigned to the respective heating circuits (1 and 2) and only displayed if these heating circuits are present and also turned on in the menu Configuration (prog.-no.

  • Page 86: Heating Circuits

    9 Settings Start of holiday (642 - 662) Entering the holiday start. End of holiday (643 - 663) Entering the holiday end. Operating level (648-668) Selection of the operating level (Reduced or Protection) for the holiday programme Important A holiday period always ends on the last day at 12:00 AM (23:59). The holiday programmes are only activated in the operation mode Automatically.
  • Page 87 9 Settings Fig.23 Heating curve diagram 2,74 2,24 °C 1,74 1,24 0,76 0,24 °C RA-sRE036B AT Outdoor temperature VT Flow temperature Determination of the heating curve gradient Enter the lowest calculated outside temperature in accordance with the climate zone (e.g. -12 °C in Frankfurt) into the diagram (see fig.) (e.g. vertical line at -12°C).
  • Page 88 9 Settings Fig.24 Summer/winter heating limit A Off E On SW Summer/winter heating limit °C T Temperature t Time x Outside temp attenuated (prog.no. 8703) The heating circuit switches to summer operation as soon as the average outside temperature over the past 24 hours rises 1°C above the value set here.
  • Page 89 9 Settings Important However, if there is a room unit (e.g. RGP) is connected and the setting "room influence" is set between 1 and 99%, the deviation of the room temperature compared to the set point is recorded and taken into consideration in the temperature control. In this way any external heat can be taken into account enabling a constant room temperature to be achieved.
  • Page 90 9 Settings protection setpoint, the heating circuit pump starts again and the mixing valve is enabled. Without room sensor the quick reduction switches the heater off depending on the outside temperature and the building time constant (prog.no. 6110) until the temperature has theoretically dropped to the reduced target value or the frost protection value.
  • Page 91 9 Settings Fig.28 Reduced setpoint increase TA1 Reduced setpoint increase start TA2 Reduced setpoint increase end TK Comfort setpoint TR Room temperature reduced setpoint TAg Outside temperature mixed When only a small heating output is required to cover demand, the reduced room setpoint can be increased in the case of cold outside temperatures.
  • Page 92 9 Settings Floor curing setp manually (851, 1151, 1451) Setting of the temperature to which manual control is carried out with floor curing function activated. Floor curing setp current (855, 1155, 1455) Display of the current floor curing setpoint. Days completed.current (856, 1156, 1456) Display of the current floor curing function day.

  • Page 93: Dhw

    9 Settings Pump speed max (883, 1183, 1483) The maximum speed for the heating circuit pump can be specified using this function. Curve readj at 50% speed (888, 1188, 1488) Correction of the flow setpoint with reduction of the pump speed by 50%. The correction is calculated using the difference from the flow setpoint according to the heating curve and current room setpoint.
  • Page 94 9 Settings Fig.30 Release depending on the time Time programs HCs: The DHW temperature will be switched over programmes of the heating circuits between the nominal DHW temperature value and the reduced nominal (example) DHW temperature value depending on the time programs. Every time, the switching-on time is moved forward.
  • Page 95 9 Settings Important If the colder storage tank temperature rises to above the legionella function setpoint -1 K, the legionella function setpoint is considered as met and the timer starts running. If the storage tank temperature drops by more than the switching difference +2K below the required legionella function setpoint, the duration has to be met again.

  • Page 96: Consumer Circuits/Swimming Pool Circuit

    9 Settings 9.2.8 Consumer circuits/swimming pool circuit In addition to the heating circuits HK1 to HK3 and the cooling circuit, additional consumers can be connected or controlled (e.g. air curtains, swimming pools, etc.). The controller can receive the temperature requests of these consumers via an Hx input and control the corresponding pumps via a QX relay output.

  • Page 97: Primary Contr/System Pump

    9 Settings Setpoint source heating (2056) When using the generator heating, the swimming pool is heated to the setpoint set here. Charging priority solar (2065) Setting of which priority the swimming pool will be solar heated. The priority for the DHW and charging buffer is set under Prog. no. 3822. Priority 1: Charging the swimming pool has top priority.
  • Page 98 9 Settings Full charging buffer (2208) Under prog. no. 4810 (full charging buffer storage tank) is selected, whether and when the buffer storage tank is fully charged despite automatic generator lock. Program no. 2208 is used to set whether the boiler takes part in the full charging or not.
  • Page 99 9 Settings Caution Limiting the boiler rise may only be performed if a modulating heat circuit pump is configured, i.e. if program no. 6085 (Function output P1) is assigned to a heating circuit pump. Temp differential nominal (2317) The spread between boiler flow temperature and boiler return temperature is called the temperature rise.
  • Page 100 9 Settings Controller delay (2450) The controller delay is used for a stabilisation of the combustion conditions, especially after a cold start. After release of the firing automation by the controller this remains on the set output for a specified time.

  • Page 101: Cascade

    9 Settings Off delay flue gas damper (2560) The control of the flue gas damper depends on the control of the fan. If the blower is no longer activated, the flue gas damper is closed. In order to be able to bridge short interruptions in operation and transitions in after- ventilation or drying the chimney, the flue gas damper is switched off with a delay.

  • Page 102: Solar

    9 Settings Auto source seq exclusion (3541) The setting for the generator exclusion is only used in connection with the activated generator sequence (program no. 3540). The generator exclusion can be used to exclude the first and/or last boiler from the automatic changeover.
  • Page 103 9 Settings Temp diff off swi pool (3817) and Charging temp min swi pool (3818) The switch-on and switch-off point of the collector pump is set with these functions. The basis for this is the temperature difference between the collector temperature and the temperature of the buffer storage tank/ swimming pool.
  • Page 104 9 Settings Waiting time parallel op (3827) Parallel operation is feasible when using solar primary pumps subject to there being sufficient solar energy available. For this, in addition to the storage tank currently being heated, the next storage tank in the priority order can also be heated in parallel.

  • Page 105: Solid Fuel Boiler

    9 Settings Pump capacity (3884) Input of the flow of the installed pump for calculation of the brought in volume for usage measurement. General yield measurement To enable precise solar yield measurement, the two additional sensors, B63 in the solar flow and B64 in the solar return, should be connected. Without these sensors a solar yield measurement is not possible.
  • Page 106 9 Settings and the forced charging of the buffer storage tank, protects it against overtemperature and maintains the layering in the storage tank as far as possible. Auto generation lock (4720) The heat generator is only put into operation if the buffer can no longer cover the current heat demand.
  • Page 107 9 Settings Temp diff on return div (4790), Temp diff off return div (4791) and Compar temp return div (4795) At the appropriate temperature difference between the return sensor B73 and the selectable comparative temperature the return is re-routed to the lower buffer storage tank section.

  • Page 108: Dhw Storage Tank

    9 Settings Full charging temp min (4811) The buffer storage tank is charged minimally o the set value. Full charging sensor (4813) With B4: For the full charging function the buffer storage tank sensor B4 is considered. With B42/B41: For the full charging function the buffer storage tank sensor B42, if not available buffer storage tank sensor B41, is considered.
  • Page 109 9 Settings Important At the first DHW release of the day, forced charging is performed. The DHW charging is also started if the DHW temperature is within the switching difference – as long as it is not less than 1 K under the setpoint.
  • Page 110 9 Settings Summer: The DHW is heated by an immersion heater if all connecting heating circuits have switched to summer mode. As soon at least one heating circuit is switched to heating mode, the DHW preparation is taken over by the boiler again. Important The immersion heater is also used if a boiler malfunction occurs or the boiler is switched off due to a boiler lock.
  • Page 111 9 Settings With prim contr/system pump (5092) No: The DHW storage tank is supplied without primary controller/feed pump. Yes: The DHW cylinder is supplied from the primary controller on/by the feed pump. With solar integration (5093) This function sets whether the domestic water storage tank can be charged using solar energy.

  • Page 112: Configuration

    9 Settings Flow setp compensation delay (5142) With the setpoint control, the heat demand is adjusted so that the intermediate circuit temperature DHW charging sensor B36 reaches its setpoint (storage tank setpoint plus intermediate circuit boost). The setpoint control can be switched on or off with the flow setpoint delay parameter ("Off"...
  • Page 113 9 Settings Thermostat: The domestic water temperature is regulated on the basis of the switching status of a thermostat connected to the DHW sensor Important No reduced mode is possible when a DHW thermostat is used. This means if reduced mode is active, the DHW preparation is blocked with the thermostat.
  • Page 114 9 Settings Request HC1/DHW only: The diverting valve is connected hydraulically only for heating circuit 1 and DHW and switches between DHW mode and heat circuit 1 mode. All other requests are not connected hydraulically via the diverting valve (DV) and the boiler pump, but rather directly connected to the boiler.
  • Page 115 9 Settings Time program 5 K13: The relay is controlled by the time program 5 according to the settings. Buffer return valve Y15: This valve must be configured for the return temperature increase/reduction or partial charging of the buffer storage tank.
  • Page 116 9 Settings Solar flow sensor B63: This sensor is required for the solar yield measurement. Solar return sensor B64: This sensor is required for the solar yield measurement. Function input H1 (5950) Function input H4 (5970) and Function input H5 (5977) Notice Not all setting options are available for all H-inputs.
  • Page 117 9 Settings Start prevention: With this input a burner start can be prevented. The boiler also remains blocked for all other protection functions. Consumer request VK1 10V/Consumer request VK2 10V: The application node external load x receives a voltage signal (DC 0...10 V) as heat request.
  • Page 118 9 Settings Frequency value 1 H4 (5973), Function value 1 H4 (5974), Frequency value 2 H4 (5975) and Function value 2 H4 (5976) Fig.36 Example for two different sensor l/min Flow rate in litres/minute curves Hx Input value to Hx E1 Input value 1 [Hz] F1 Function value 1 E2 Input value 2[Hz]...

  • Page 119: Lpb System

    9 Settings Water pressure min (6181) A maintenance message is indicated from this set water pressure. The boiler output is reduced by 20% to protect the boiler. The message is only reset when the set pressure has been exceeded by 0.2 bar. Save sensors (6200) Sensor modes can be saved under prog.
  • Page 120 9 Settings Bus power supply function (6604) Off: The controller does not provide the bus power supply. Automatically: The bus power supply is switched on and off by the controller in accordance with the power demand of the bus system. Bus power supply state (6605) Off: The bus system power supply by the controller is currently inactive.

  • Page 121: Modbus

    9 Settings All HCs in system: The domestic hot water charging takes into consideration heating circuits/cooling circuit for all of the controllers in the system. Important For all settings, the controllers that are in holiday status are also taken into consideration for the DHW preparation. Note OT limit ext source (6632) Additional generators connected via the LBP can be locked or released according to their own parameter based on the outside temperature (e.g.

  • Page 122: Maintenance / Special Operation

    9 Settings Burn ctrl phase lockout pos (6706) Phase during which the fault occurred which led to the failure. Reset alarm relay (6710) An output relay QX, programmed as an alarm relay can be reset via this setting. Flow temp 1 alarm (6740), Flow temp 2 alarm (6741), Flow temp 3 alarm (6742), Boiler temp alarm (6743) , DHW charging alarm (6745) Setting the time after which a fault message will be triggered in case of...
  • Page 123 9 Settings Important The function is switched off by the settingOff or automatically if the maximum boiler temperature is reached. It can also be directly activated via the chimney sweep button. Manual control (7140) Activation of manual control. If the manual control function is activated the boiler is controlled to the setpoint manual control.

  • Page 124: Configuration Of Extension Modules

    9 Settings The stick status is shown below: No stick: The LMS control has not detected a stick (the stick may not be inserted). Stick ready: Basic condition, stick is detected, no action active, no error present. Writing on stick: Data is copied (backup) from the LMS control to the stick.
  • Page 125 9 Settings Flow sensor HC2 Flow sensor HC3 Flow sensor primary control Relay output QX21 module 1 (7301), Relay output QX22 module 1 (7302), Relay output QX23 module 1 (7303), Relay output QX21 module 2 (7376), Relay output QX22 module 2 (7377), Relay output QX23 module 2 (7378), Relay output QX21 module 3 (7451), Relay output QX22 module 3 (7452) and Relay output QX23 module 3 (7453)
  • Page 126 9 Settings DHW interm circ pump Q33: Charging pump for DHW cylinder with external heat exchanger. Heat request K27: as soon as a heat demand exists in the system, the output K27 will be activated. Heat circuit pump HC1 Q2/Heat circuit pump HC2 Q6: The relay is used for actuating the heating circuit pump Q2/Q6.
  • Page 127 9 Settings Heat generation lock: the heat generator is locked through connecting terminal H2/H21. All temperature demands for heating circuits and DHW are ignored. The boiler frost protection function is maintained. Important The chimney sweeper function can be applied in spite of the heat generation lock.

  • Page 128: Input/Output Test

    9 Settings Funct input EX21 module 1 (7342) , Funct input EX21 module 2 (7417) and Funct input EX21 module 3 (7492) None: No function. Limit thermostat HC: If the extension module is used for the heating circuit, an external temperature monitor can be install in at the inlet EX21 (e.g.
  • Page 129 9 Settings Tab.19 Status table heating circuit The following messages are possible under Heating circuit: End user (Eu) Commissioning, Engineer (menu Status) Limiter has tripped Limiter has tripped Manual control active Manual control active Floor curing function active Floor curing function active Heating mode restricted Overtemp prot active Restricted, boiler protection...
  • Page 130 9 Settings End user (Eu) Commissioning, Engineer (menu Status) Charging, nominal setp Charging, reduced setp Frost protection active Frost protection active Frost prot instant WH Overrun active Overrun active Standby charging Standby charging Charged Charged, max st tank temp Charged, max charging temp Charged, legionella temp Charged, nominal temp Charged, reduced temp...
  • Page 131 9 Settings Tab.22 Status table solar The following messages are possible under Solar: End user (Eu) Commissioning, Engineer (menu Status) Manual control active Manual control active Fault Fault Frost prot collector active Frost prot collector active Recooling active Recooling active Max st tank temp reached Max st tank temp reached Evaporation prot active...
  • Page 132 9 Settings End user (Eu) Commissioning, Engineer (menu Status) Lockout position Lockout position Start prevention Start prevention In operation In operation Startup Safety time Prepurge Startup Postpurge Shutdown Home run Standby Standby Tab.25 State table buffer storage tank The following messages are possible under Buffer storage tank: End user (Eu) Commissioning, Engineer (menu Status)

  • Page 133: Diagnostics Cascade/Heat Generation/Consumers

    9 Settings 9.2.25 Diagnostics cascade/heat generation/consumers Diagnostics cascade/heat generation/consumers (8100-9058) Displays of different setpoint and actual values, relay switching statuses and counter statuses for diagnostics purposes. Gas energy There are 6 energy meters available, comprising the estimated gas energy used with the aid of the fan speed and a linear approximation of the actual burner output.

  • Page 134: Info Option

    9 Settings 9.2.27 Info option Different information values are displayed depending on the operating conditions. In addition, information about the status is displayed. 7703301 - 01 - 16072018...

  • Page 135: 10 Maintenance

    10 Maintenance 10 Maintenance 10.1 General 10.1.1 General instructions In heating and air conditioning systems, a regular inspection and maintenance as required by qualified personnel contribute to correct operation according to the product specification, and therefore to ensuring high efficiency and low environmental pollution in the long term. Danger of electric shock Before any work, switch off the mains supply to the boiler.

  • Page 136: Lifetime Of Safety-Relevant Components

    If the lifetime Potterton in accordance with the following table is exceeded, recommends replacing the relevant components. Design-related rated lifetime Safety-relevant compo­...

  • Page 137: Standard Inspection And Maintenance Operations

    10 Maintenance Phase number Display Operating state Description of function Standby (no heat demands) Burner on stand-by THL1 Fan start-up Self-test for burner start and fan start-up THL1A Pre-purging time Pre-purging, fan deceleration time to starting load speed TBRE Waiting time Internal safety tests Ignition phase Ignition and start of safety time for flame formation, ionisation...
  • Page 138 10 Maintenance Fig.38 Loosening the flue gas silencer 5. Remove the hose lines of the air pressure switch from the venturi pipe 6. Remove the screws on the flange on the venturi pipe 7. Loosen the flue gas silencer with seal (in the flange) from the venturi pipe RA-0000228 Fig.39...

  • Page 139: Checking Combustion Room Insulation

    10 Maintenance Danger Risk to life due to explosion, fire or escaping flue gas. Before commissioning the boiler, the parts of the system through which fuel and flue gas flow must be checked for leaks. If there are any leaks in the pipelines, the seals must be replaced. If there are any leaks due to defective components, the components in question must be replaced.

  • Page 140: Cleaning The Burner Pipe

    10 Maintenance Fig.42 Inserting the combustion room 3. Insert a retaining clip with the angled tips from behind into the upper insulation. insulating panel 4. Insert the insulating panels 4.1. Insert the upper insulating panel 4.2. Insert the left insulating panel 4.3.

  • Page 141: Cleaning The Fan

    10 Maintenance Fig.44 Removal of the flue gas collection 1. Remove screws and remove cover of the flue gas collection pan with pan cover seal RA-0000236 2. Clean the heat exchanger with a brush or rinse with water 3. Remove deposits from the exhaust collection pan RA-0000237 4.

  • Page 142: Changing The Ignition Electrodes

    10 Maintenance Fig.45 Removing the fan 1. Remove nuts with washers and release the the fan with seal from the burner cover 2. Remove screws and release venturi pipe, incl. gas valve with seal from the fan 3. Clean fan with compressed air 4.

  • Page 143: 10.3.10 Changing The Ionization Electrode

    10 Maintenance Danger of electric shock Danger to life due to electric current! Do not touch plug contacts during the ignition process! The ionization electrode must always be in contact with the flame. During burner operation, the measured ionization flow must display the following values: at minimum power >...

  • Page 144: 10.3.12 Protection Against Contact

    10 Maintenance 10.3.12 Protection against contact Danger of electric shock Danger to life due by missing shock-proof protection. To ensure shock-proof protection, all parts of the boiler to be screwed on – the casing parts in particular – must be screwed on correctly after work has been completed.
  • Page 145 10 Maintenance 3. Remove the protective cap from the boiler fill and drain valve (BFD valve) on the return manifold of the EC five and screw the hose nozzle in place 4. Push the water hose onto the hose nozzle RA-0000248 5.

  • Page 146: 11 Troubleshooting

    11 Troubleshooting 11 Troubleshooting 11.1 Fault code table The following is an extract from the fault code table. If other fault codes are displayed, please inform the installer. Fault Error description Explanations/causes code No fault Outside temp sensor fault Check connection or outside temp sensor, emergency opera­ tion Boiler temperature 1 sensor fault Check connection, inform heating specialist...
  • Page 147 11 Troubleshooting Fault Error description Explanations/causes code DHW charging monitoring Legionnaire's disease germs temperature not reached Flame failure during operation Gas pressure Monitor fault Lack of gas, contact GW opened, external temperature moni­ No flame during the safety time Reset, if the fault re-occurs several times contact installer, lack of gas, polarity of mains connection, safety period, check 1) 3) ignition electrode and ionization current...

  • Page 148: Fault Finding

    11 Troubleshooting Fault Error description Explanations/causes code Storage buffer address error Primary controller/supply pump address error Low-loss header address error Common flow sensor B10 missing Flow temperature 3 (Heating circuit 3) monitoring Temperature monitor HK3 Expansion module 3 fault (collective fault) Repetition counter internal fault expired Repetition counter fan fault expired External light...
  • Page 149 11 Troubleshooting Burner does not start: No voltage at the control and regulating centre Fault code No “burner ON” signal from the heating circuit control (see table ) Gas tap closed No ignition Burner goes into fault mode: Without flame formation: No ignition Ionization electrode has ground connection Ionization electrode is not connected...

  • Page 150: 12 Decommissioning

    12 Decommissioning 12 Decommissioning 12.1 Decommissioning procedure 12.1.1 Decommissioning the domestic water storage tank Caution Risk of water damage! Ensure the stored water can flow unimpeded into the drain. The domestic water storage tank is decommissioned as follows: 1. Close the disconnector valve to stop the cold water supply. 2.

  • Page 151: 13 Disposal/Recycling

    Please follow the legal requirements applicable to disposal in your country. 13.2 Appliance disposal The appliance can be returned to Potterton for disposal via a specialist company. The manufacturer undertakes to recycle the appliance correctly. Important The appliance is recycled by a disposal company. If possible, the materials, especially the plastics, are identified.

  • Page 152: 14 Appendix

    14 Appendix 14 Appendix 14.1 Declaration of conformity 7703301 - 01 - 16072018...

  • Page 153: Index

    Index Index Additives ........28 Heat exchanger .
  • Page 154 Index System log ........54 Top up heating water .
  • Page 155 © Copyright All technical and technological information contained in these technical instructions, as well as any drawings and technical descriptions supplied, remain our property and shall not be multiplied without our prior consent in writing. Subject to alterations.
  • Page 156 Potterton Commercial Part of Baxi Heating UK Ltd | Innovation House Oaklands Business Centre Oaklands Park | Wokingham RG41 2FD Phone 0345 070 1055 | www.potertoncommercial.co.uk 7703301 - 01 - 16072018...

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