Potterton Gold HE A Range Installation & Service Instructions Manual

Gold he a range condensing combination boiler.
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Installation & Service Instructions
Gold HE
Combination Boiler
These instructions include the Benchmark Commissioning
Checklist and should be left with the user for safe keeping.

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   Summary of Contents for Potterton Gold HE A Range

  • Page 1

    You can rely on Installation & Service Instructions Gold HE Range Condensing Combination Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2008...

  • Page 2: Natural Gas

    Natural Gas Potterton Gold Combi 24 HE G.C.N 47 393 18 Potterton Gold Combi 28 HE G.C.N 47 393 19 Potterton Gold Combi 33 HE G.C.N 47 393 20 © Baxi Heating UK Ltd 2008 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...

  • Page 3

    Competent Person's Self Certification Scheme Install and Commission this appliance to manufacturer's instructions Complete the Benchmark Checklist If you notify via CORGI Scheme, CORGI will then notify the relevant Local Authority Building Control Scheme on member's behalf Scheme Members only Call CORGI on: 0800 408 1007 or log onto: www.corgi-notify.com...

  • Page 4

    Crockford Lane, Basingstoke. RG24 8WG or check online at www.trustcorgi.com The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency) Regulations 1993 N 3083” and is deemed to meet the requirements of Directive 92/42/EEC on the energy efficiency requirements for new hot water boilers fired with...

  • Page 5

    Where possible transport the boiler using a sack truck or other suitable trolley. Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the ‘Installation’ section of these instructions for recommended lift points.

  • Page 6: Table Of Contents

    © Baxi Heating UK Ltd 2008 CONTENTS Section Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Flue Options Plume Displacement 10.0 Installation 11.0 Commissioning 12.0 Completion 13.0 Servicing 14.0 Changing Components 15.0 Combustion Check 16.0 Electrical 17.0...

  • Page 7: Introduction

    It is room sealed and fan assisted, and will serve central heating and mains fed domestic hot water. 2. The boiler is set to give a maximum output of :- 24 models - 24 kW DHW 21 kW CH (Condensing) 28 models - 28 kW DHW 25.9 kW CH (Condensing)

  • Page 8: General Layout

    Reset © Baxi Heating UK Ltd 2008 2.0 General Layout Layout Expansion Vessel Automatic Air Vent DHW Plate Heat Exchanger Circulation Pump Drain Off Point Pressure Relief Valve Optional Integral Timer Position Central Heating System Pressure Gauge Control Box 3-Way Valve Assembly Condensate Trap Flame Sensing Electrode Spark Electrode...

  • Page 9: Appliance Operation

    (see Section 2.1) in the domestic hot water and central heating position. If the system temperature falls below 5° C then the boiler will fire on its minimum setting until a flow temperature of 30° C is reached.

  • Page 10: Technical Data

    5 mm Min R.H. Side 5 mm Min (In Operation) Weights (kg) (24) (28) (33) Packaged Boiler Carton 48.6 49.2 Installation Lift Weight 43.6 44.2 Gold Combi 24, 28 & 33 HE NO x Class Central Heating Primary Circuit Pressures...

  • Page 11: Dimensions And Fixings

    At least 1.5° 360° Orientation 32.5 mm Condensate Drain 65 mm Heating Flow (22mm) © Baxi Heating UK Ltd 2008 Dimensions A 780mm B 345mm C 450mm D 116mm Ø Min. E 185mm (207mm for 80/125mm flue systems) F 145mm G 131mm H 180mm 270mm...

  • Page 12: System Details

    This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems. • When fitting new systems flux will be evident within the system, which can lead to damage of system components.

  • Page 13

    Consideration must be given to the possibility that boiling water/steam could discharge from the pipe. 4. A remote relief valve kit is available to enable the boiler to be installed in cellars or similar locations below outside ground level (kit no. 5121379).

  • Page 14

    6. The boiler’s maximum working mains pressure is 8 bar, therefore all pipework, connections, fittings, etc. should be suitable for pressures in excess of 8 bar. A pressure reducing valve must be fitted for pressures in excess of 8 bar.

  • Page 15: Site Requirements

    780mm 3. If the boiler is fitted in a room containing a bath or shower reference must be made to the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building Regulations.

  • Page 16

    Bath & Shower Rooms 1. As the boiler is fitted with an integral timer when installed in a room containing a bath or shower it cannot be fitted in zones 1 or 2. (Figs. 11 & 12 shows zone dimensions for a bathtub.

  • Page 17

    6. It is advisable to keep the condensate pipe internal. 7. External runs greater than 3 metres or runs in cold areas should use 32mm waste pipe. 8. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run.

  • Page 18

    Air Inlet 7.0 Site Requirements Flue NOTE: Due to the nature of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. 1. The following guidelines indicate the general requirements for siting balanced flue terminals.

  • Page 19: Flue Options

    - see Section 9.0 NOTE: Horizontal flue pipes should always be installed with a fall of at least 1.5° from the terminal to allow condensate to run back to the boiler. This bend is equivalent to 1 metre Total equivalent length = A+B+C+2x90°Bends...

  • Page 20

    Total Equivalent Length = A+B+C+1x90°Bend All vertical and angled runs must be included, measured from the boiler adaptor (point X) to the joint with the flue terminal (point Y). One 91.5° bend or two 135° bends can be included without reduction of the flue length.

  • Page 21

    FLUE GROUP N Twin Flue System 80mm diameter Flue Extension (pair) 1000mm Flue Bend (pair) 90° Flue Bend (2 pair) 135° Vertical Flue Boiler Adaptor Kit Vertical Flue Adaptor Pipe Support (pair) 80mm Flue Termination Kit (horizontal termination) 80mm FLUE GROUP G...

  • Page 22

    Air duct adaptor 1. Undo the screws securing the blanking plate to the boiler top panel. Discard the plate. 2. There are three restrictor plates supplied in the kit. One marked ‘23’...

  • Page 23

    IMPORTANT: If the boiler is not fitted immediately after the flue system, temporary precautions must be taken to prevent rain entry into the room of installation. Any precautionary measures must be removed prior to commissioning the boiler.

  • Page 24: Plume Displacement

    There must be a constant fall along the entire length of the flue system from the outlet back to the boiler. 4. It is possible to reduce or increase (with the addition of extensions) the length of either or both the 60/100 concentric and 60Ø...

  • Page 25

    Concentric 60/100 Flue (metres) Y Example 1 Flue Lengths - Not Permissible Concentric 60/100 Flue (metres) Y Example 3 Flue Lengths - OK 60Ø Exhaust 93° Elbow Concentric 60/100 Flue Fig. 26 Additional Accessories A - 93° Elbow 5121369 B - 45° Elbow (Pair) 5121370 C - 1 metre 60Ø...

  • Page 26

    7. Ensure that the concentric assembly and any extensions fall back to the boiler at an angle of at least 1.5° and that the external air inlet is to the bottom. 8. Use suitable brackets to support the concentric assembly and any extensions, and make good inside and outside.

  • Page 27

    Plume Outlet Fig. 34 Fig. 35 30mm Fig. 36 200mm Min. Fig. 37 © Baxi Heating UK Ltd 2008 Elbow 70° Outlet Spigot 9.0 Plume Displacement General Fitting Notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø...

  • Page 28: Installation

    1. Remove staples, open flaps and remove the cardboard sheet. Remove the polystyrene side pieces and literature. Two people can then lift out the boiler (Figs. 39 & 40). 2. After considering the site requirements (see Section 7.0) position the fixing template on the wall ensuring it is level both horizontally and vertically.

  • Page 29

    10.0 Installation 10.3 Fitting the Filling Loop 1. The filling loop supplied with the boiler can be connected to the taps on the wall plate at this point. 2. The filling loop is to be connected between the mains cold water inlet and central heating return isolation taps.

  • Page 30

    1. Lift the boiler using the Lifting Points as shown by the shaded areas (Fig. 45). The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig. 46) (see Safe Manual Handling page 5).

  • Page 31

    (Fig. 48). 2. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (Fig. 50). The elbow is fully engaged when there is a distance of 20mm from the adaptor to the indicator line (Fig.

  • Page 32

    (Fig. 53). 8. Insert the flue through the hole in the wall. Fit the elbow to the boiler adaptor, ensuring that it is pushed fully in. 9. Draw the flue back through the wall and engage it in the elbow.

  • Page 33

    10.0 Installation 10.8 Making The Electrical Connections The boiler is fitted with a 1.3m length of 3 core cable. This can be connected to the fused 3A 230V 50H NOTE: Both the Live and Neutral connections are fused. To connect an external control proceed as follows:- 1.

  • Page 34: Commissioning

    3. Open all hot water taps to purge the DHW system. 4. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler. 5. Open the screw on the automatic air vent on the pump body (Fig.

  • Page 35

    ( ). The current boiler temperature is shown on the display. 4. To check the gas rate it is necessary to set the boiler to ‘Calibration Mode’. 5. Turn both temperature control knobs fully anticlockwise, then quickly turn the DHW temperature knob twice and back fully anticlockwise (Fig.

  • Page 36

    Time Pointer Constant Timed Rotate to adjust time GRASSLIN On Position Off Position Time Pointer © Baxi Heating UK Ltd 2008 11.0 Commissioning 11.3 Setting the Timer The Electro-Mechanical Timer allows the central heating system to be set every 15 minutes. Using the three position switch the timer will allow either constant operation, timed operation or central heating off.

  • Page 37: Completion

    12.0 Completion 12.1 Completion Case Front Panel 1. Instruct the user in the operation of the boiler and system explaining the operational sequence. 2. Set the central heating and hot water temperature control knobs to the requirements of the user.

  • Page 38: Servicing

    Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person in accordance with B.S. 7967-4:2007. If a suitably calibrated combustion analyser is available it may not be necessary to perform a full strip down of the appliance.

  • Page 39

    21. Rinse the filter thoroughly in clean water and reassemble in reverse order. 22. Turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler. Blanking Cold Water Inlet Tap 23.

  • Page 40: Changing Components

    When the component has been changed turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler before recommissioning. See Section 13.1 “Annual Servicing” for removal of case panel, door etc.

  • Page 41

    Venturi Injector Cover Gas Inlet Pipe Fig. 83 Burner Gasket Venturi Injector Collector Fig. 82 Fig. 84 © Baxi Heating UK Ltd 2008 14.0 Changing Components 14.3 1. Undo the nut on the gas inlet pipe to the venturi (Fig. 83) and pull the sensing pipe off the fan.

  • Page 42

    Cover Burner Gasket Extension Piece (24 & 28 models) Collector Fig. 85 Rear Insulation Spark Electrode Collector Electrode Sensing Leads Electrode © Baxi Heating UK Ltd 2008 Venturi Heat Exchanger Venturi Cover Insulation Seal Fig. 86 14.0 Changing Components 14.6 Burner (Fig.

  • Page 43

    Electrical Plug Flue/Heat Exchanger Thermostat Sensor Fig. 87 Flow Pipe Central Heating Temperature Sensor Safety Thermostat Fig. 88 Pressure Sensor Fig. 89 DHW Temperature Sensor © Baxi Heating UK Ltd 2008 14.0 Changing Components 14.8 Flue/Heat Exchanger Thermostat Sensor (Fig. 87) 1.

  • Page 44

    14.12 Pump - Head Only (Fig. 91) 1. Drain the boiler primary circuit and remove the socket head screws securing the pump head to the body and draw the head away. 2. Undo the screw on the pump wiring cover and remove the cover.

  • Page 45

    14.0 Changing Components 14.15 Pressure Gauge (Figs. 94 & 95) 1. Drain the boiler primary circuit and undo the nut on the pressure gauge capillary. 2. Undo the screws securing the gauge retaining bracket. 3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining bracket.

  • Page 46

    6. Undo the nuts on the tap rail under the boiler. Remove the screws securing the valve assembly to the boiler bottom panel and plate heat exchanger.

  • Page 47

    Control Box Cover Fig. 101 P.C.B. Selector Switch Facia Selector Switch Knob Fig. 102 © Baxi Heating UK Ltd 2008 14.0 Changing Components 14.20 P.C.B. (Fig. 102) 1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins.

  • Page 48

    Examine the ‘O’ ring seals, replace if necessary. 6. Reassemble in reverse order. NOTE: To assist the boiler to light prior to final setting, use a suitable hexagon key to wind out the Gas/Air adjustment screw until it is flush with the valve body, then turn the screw 4 full turns clockwise (Fig.

  • Page 49: Combustion Check

    ) may be checked using a suitably calibrated analyser after running the boiler for several minutes. 2. To do this it is necessary to set the boiler to ‘Calibration Mode’. 3. Ensure that all external controls are calling for heat. The actual current boiler temperature is shown on the display.

  • Page 50: Electrical

    NTC Sensor Hall Effect Sensor Water Pressure Switch Control PCB X501 Flame Sensing Electrode Link Mains Input Cable © Baxi Heating UK Ltd 2008 Central Heating NTC Sensor Overheat Stat X400 X401 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Spark Generator...

  • Page 51: Short Parts List

    © Baxi Heating UK Ltd 2008 17.0 Short Parts List Short Parts List G.C. Description Manufacturers Motor 3way Valve Igniter Electrode Sensing Electrode Gas Valve Hall Effect Sensor Burner 24 Burner 28 Burner 33 Water Pressure Switch Plate Heat Exchanger 24 Plate Heat Exchanger 28/33 Pump NTC Sensor...

  • Page 52: Fault Finding, Baxi Heating Uk Ltd

    18.2 Error Codes 1. If a fault occurs on the boiler an error code may be shown by the facia display. 2. The codes are either two or three digit, preceded by the letter 'E'. For example, code E133 will be displayed by 'E1' alternating with '33'.

  • Page 53

    Refer to Section 16.0 “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence (do Turn selector switch to The display illuminates Error 110 flashing Error 130 flashing Error 133 flashing Error 20, 28 or 50 flashing Error 119 flashing Turn Central Heating thermostat to Maximum.

  • Page 54

    Domestic Hot Water - Follow operational sequence Turn selector switch to The display illuminates Error 110 flashing Error 133 flashing Error 20, 28 or 50 flashing Error 119 flashing Turn Domestic Hot Water thermostat to Maximum. Open DHW tap fully. DHW Hall Effect sensor operated (red neon on the sensor illuminated...

  • Page 55: Fault Finding Solutions Sections

    Fault Finding Solutions Sections Is there 230V at: Main terminals L and N Main terminal fuse PCB - X1 connector terminals 1,2 Is there 230V at: Pump If pump jammed, release PCB - X3 connector terminals 3 & 4 Change pump supply cable CH system pressure less than 0.5 bar Check the tap of the automatic air vent is opened...

  • Page 56

    E20 or E50 - Temperature sensors faulty. Cold resistance approximately 10kΩ @ 25° C (DHW and CH sensors) 20kΩ @ 25° C (Flue sensor) (resistance reduces with increase in temp.) E28 - Incorrect PCB fitted Check and correct the connection of the tube between the venturi and gas valve Gas at burner PCB - X3 connector is 230V AC across...

  • Page 57

    Check the gas supply pressure: For Natural Gas greater than 10 - 11 mbar Check and correct if necessary 1. The mechanical set of the gas valve (CO2 values - see instruction) 2. Flame sensing electrode and lead connections 3. Flame sensing electrode position Flame current should be more than 0.5 μA Overheat thermostat operated or faulty, i.e.

  • Page 58


  • Page 59: Service Interval Record

    Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls SERVICE 1...

  • Page 60

    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.

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