Potterton Gold 24 HE Installation & Service Instructions Manual

Potterton Gold 24 HE Installation & Service Instructions Manual

Gold combi he series
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Installation & Service Instructions
Gold Combi HE
Range
This is a Wall Mounted Powered Flue Condensing Combination Boiler Gas Fired Central Heating Unit.
The boiler meets the requirements of Statutory Instrument " The Boiler (Efficiency) Regulations 1993 N
o
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 liquid or gaseous fuels:-
Type test for purpose of Regulation 5 certified by:
Notified Body 0085.
Product/Production certified by:
Notified Body 0085.
For use in GB/IE only.
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 24 HE

  • Page 1 Installation & Service Instructions Gold Combi HE Range This is a Wall Mounted Powered Flue Condensing Combination Boiler Gas Fired Central Heating Unit. 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 liquid or gaseous fuels:- Type test for purpose of Regulation 5 certified by:...
  • Page 2 Potterton is a member of the Benchmark initiative and fully supports the aims of the programme. Its aim is to improve the standards of installation and commissioning...
  • Page 3 INSTALLER NOTIFICATION GUIDELINES Install and Commission this appliance to manufacturer's instructions Complete the Benchmark Checklist Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme If you notify via CORGI Scheme, Contact your relevant Local CORGI will then notify the Authority Building Control relevant Local Authority (LABC) who will arrange...
  • Page 4 LEGISLATION IMPORTANT - Installation, Commissioning, Service & Repair Potterton declare that no substances harmful to health are contained in the appliance or used This appliance must be installed in accordance with the manufacturer’s during appliance manufacture. instructions and the regulations in force. Read the instructions fully before installing or using the appliance.
  • Page 5: Table Of Contents

    CONTENTS Section Page Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Installation Commissioning 10.0 Completion 11.0 Servicing 12.0 Changing Components 13.0 Combustion Check 14.0 Electrical 15.0 Short Parts List 16.0 Fault Finding 17.0 Notes Benchmark Checklist Publication No.
  • Page 6: Introduction

    INTRODUCTION Description 1. The Potterton Gold Combi HE is a fully automatic gas fired wall mounted condensing combination boiler. It is room sealed and fan assisted, and will serve Case Front Panel central heating and mains fed domestic hot water.
  • Page 7: General Layout

    GENERAL LAYOUT Layout Expansion Vessel Automatic Air Vent DHW Plate Heat Exchanger Circulation Pump Drain Off Point Pressure Relief Valve Integral Timer Position Central Heating System Pressure Gauge Control Box 3-Way Valve Assembly Condensate Trap Flame Sensing Electrode Spark Electrode Primary Heat Exchanger Fan Assembly On/Off/Reset Selector Switch...
  • Page 8: Appliance Operation

    APPLIANCE OPERATION Central Heating Mode (Fig. 2) Central Heating Circuit 1. With a demand for heating, the pump circulates water through the primary circuit. 2. Once main burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor.
  • Page 9: Technical Data

    (Appliance must be connected to an Installation Lift Weight earthed supply) Pump - Available Head SEDBUK Declaration For Gold 24 HE The seasonal efficiency (SEDBUK) is 90.1% Band A This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by 0085.
  • Page 10 (Appliance must be connected to an Installation Lift Weight earthed supply) Pump - Available Head SEDBUK Declaration For Gold 24 HE The seasonal efficiency (SEDBUK) is 90.1% Band A This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by 0085.
  • Page 11 (Appliance must be connected to an Installation Lift Weight earthed supply) Pump - Available Head SEDBUK Declaration For Gold 24 HE The seasonal efficiency (SEDBUK) is 90.1% Band A This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by 0085.
  • Page 12: Dimensions And Fixings

    DIMENSIONS AND FIXINGS Dimensions A 780mm B 345mm C 450mm D 116mm Ø Min. E 185mm F 145mm G 131mm H 180mm 360° Orientation Tube Ø 100mm Tap Rail 32.5 mm Condensate Drain 65 mm 65 mm 65 mm 65 mm 65 mm Heating Heating...
  • Page 13: System Details

    SYSTEM DETAILS Information 1. The Potterton Gold HE Condensing Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN). a) IRN 001 - See text of entry for installation requirements and notes.
  • Page 14 SYSTEM DETAILS System Filling and Pressurising 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. 2. There are connection points on the mains cold water inlet and central heating return isolating taps (Fig.
  • Page 15 SYSTEM DETAILS Domestic Hot Water Circuit (Fig. 7) 1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations. Other Tap Outlets 2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation Boiler R17 to R24 of the Water Regulations Guide.
  • Page 16: Site Requirements

    SITE REQUIREMENTS 450mm 5mm Min 5mm Min Location 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and 200mm Min discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply.
  • Page 17 SITE REQUIREMENTS Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. Gas Supply 1.
  • Page 18 SITE REQUIREMENTS Condensate Drain Termination to an internal soil Boiler and vent pipe FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5°...
  • Page 19 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 20 SITE REQUIREMENTS Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 685mm from elbow to terminal (Fig. 13). The maximum permissible equivalent flue length 10 metres Flue Trim 1. The rubber flue trim supplied may be fitted to either Fig.
  • Page 21 SITE REQUIREMENTS 7.11 Flue Options 1. The Potterton Gold HE can be fitted with flue systems as illustrated. 2. The standard flue is suitable only for horizontal termination applications. 3. Maximum permissible equivalent flue lengths are:- Horizontal Concentric 10 metres...
  • Page 22: Installation

    INSTALLATION Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). 145mm 1. 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 23 INSTALLATION 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. 3.
  • Page 24 Wall Plate INSTALLATION Fitting The Boiler 1. Remove the sealing caps from the boiler connections. 2. Lift the boiler using the lower edges. Engage the slots at the top rear of the boiler on the wall plate (Fig. 18). 3. Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections.
  • Page 25 INSTALLATION Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths between 100mm minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (Fig. 20). 2.
  • Page 26 INSTALLATION Fitting the Flue (Cont) Waste 5. Mark dimension ‘Y’ on the flue as shown (Fig. 23). Carefully cut the waste material from the flue, ensuring that the ducts are square and free from burrs. 6. The inner flue duct support bracket may be in the Flue waste portion of the flue.
  • Page 27 INSTALLATION Making The Electrical Connections To connect the mains input cable proceed as follows:- 1. Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel. Control Box Cover 2.
  • Page 28: Commissioning

    COMMISSIONING Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 Screw when commissioning the boiler. 2. Open the mains water supply to the boiler. 3. Open all hot water taps to purge the DHW system. Automatic Air Vent 4.
  • Page 29 COMMISSIONING 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 Time Pointer either constant operation, timed operation or central heating off. Constant Move the switch button by sliding to the desired position.
  • Page 30 COMMISSIONING Checking 1. The gas valve is factory set and the burner pressure cannot be measured as it is altered by suction of the fan and modulates as demand on the boiler alters. The gas supply pressure should be 20mb. 2.
  • Page 31: Completion

    10.0 COMPLETION 10.1 Completion Case Front Panel 1. Instruct the user in the operation of the boiler and system including the integral timer, explaining the operational sequence. 2. Set the central heating and hot water temperature control knobs to the requirements of the user. 3.
  • Page 32: Servicing

    11.0 SERVICING 11 .1 Annual Servicing Case Front Panel 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person. If a combustion analyser is available the CO can be checked and adjusted - see Section 13.0.
  • Page 33 11.0 SERVICING 11.1 Annual Servicing (Cont) Burner Viewing Window 7. Undo the nut on the gas inlet pipe to the venturi (Fig. 42) and pull the sensing pipe off the fan. 7.5 ± 1 8. Disconnect the electrode leads, noting their position, and the fan electrical plugs (Fig.
  • Page 34: Changing Components

    12.0 CHANGING COMPONENTS IMPORTANT: When changing components ensure that both the gas and electrical supplies to Bracket the boiler are isolated before any work is started. When the component has been changed turn the selector switch fully anticlockwise against the Igniter spring pressure to the reset position and hold for 5 seconds to reset the boiler before...
  • Page 35 12.0 CHANGING COMPONENTS 12.3 Fan (Fig. 48) 1. Undo the nut on the gas inlet pipe to the venturi (Fig. 49) and pull the sensing pipe off the fan. 2. Disconnect the electrode leads, noting their position and disconnect the fan electrical plugs. 3.
  • Page 36 Cover 12.0 CHANGING COMPONENTS 12.6 Burner (Fig. 51) Burner 1. Undo the screws securing the collector to the Gasket venturi and extension piece. Remove this extension Extension Piece piece from the cover (on 24 and 28 models). (Not on 33 model) 2.
  • Page 37 12.0 CHANGING COMPONENTS 12.8 Flue/Heat Exchanger Thermostat Electrical Sensor (Fig. 53) Plug Flue/Heat Exchanger 1. Ease the retaining tab on the sensor away and Thermostat Sensor disconnect the electrical plug. 2. Turn the sensor 90 anticlockwise to remove - it is a bayonet connection.
  • Page 38 12.0 CHANGING COMPONENTS 12.13 Pump - Head Only (Fig. 56) 1. Drain the 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 39 12.0 CHANGING COMPONENTS 12.16 Pressure Gauge (Figs. 59 & 60) Gauge Retaining Bracket 1. Drain the 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 Pressure Gauge remove the retaining bracket.
  • Page 40 12.0 CHANGING COMPONENTS 12.19 Plate Heat Exchanger (Fig. 63) 1. Drain the primary circuit and remove the gas valve Plate Heat Exchanger as described in section 12.23. 2. While supporting the heat exchanger undo the screws securing it to the brass manifolds. 3.
  • Page 41 12.0 CHANGING COMPONENTS 12.21 P.C.B. (Fig. 67) 1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins. 2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots.
  • Page 42 12.0 CHANGING COMPONENTS 12.23 Gas Valve (Fig. 68) 1. Turn the gas cock off and undo the nut on the gas Venturi Inlet feed elbow under the boiler. Pipe 2. Remove the screws securing the inlet pipe flange Outlet Adaptor to the boiler bottom panel.
  • Page 43: Combustion Check

    13.0 COMBUSTION CHECK 13.1 Checking the CO 1. The combustion (CO ) 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.
  • Page 44: Electrical

    14.0 ELECTRICAL 14.1 Illustrated Wiring Diagram Central Heating NTC Sensor NTC Sensor Overheat Stat Hall Effect Sensor Water Pressure Flue Sensor Switch X400 X401 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Timer Control PCB X501...
  • Page 45: Short Parts List

    15.0 SHORT PARTS LIST Short Parts List G.C. Description Manufacturers Part No. 5114684 Motor 3way Valve 248733 Igniter Electrode 5114702 Sensing Electrode 5114703 Gas Valve 5114734 Hall Effect Sensor 5114767 Burner 24 & 28 5114697 Burner 33 5114698 Water Pressure Switch 5114748 Plate Heat Exchanger 5114708...
  • Page 46: Fault Finding

    16.0 FAULT FINDING Carry out initial fault finding checks NOTE: When instructed to turn the 1. Check that gas, water and electrical supplies are selector to the reset position turn the available at the boiler. selector switch fully anticlockwise against the spring pressure to the 2.
  • Page 47 16.0 FAULT FINDING Refer to Section 14.0 “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence Turn selector switch to Go to section ‘A’ The display illuminates Error 110 flashing If the error 110 is still Turn the selector switch to Error 130 flashing flashing.
  • Page 48 16.0 FAULT FINDING Domestic Hot Water - Follow operational sequence Turn selector switch to Go to section ‘A’ The display illuminates Error 110 flashing Turn the selector switch to If the error 110 is still Error 133 flashing flashing. Go to section ‘J’ reset position for 5 seconds Error 20, 28 or 50 flashing Go to section ‘E’...
  • Page 49: Fault Finding Solutions Sections

    16.0 FAULT FINDING Fault Finding Solutions Sections Is there 230V at: Main terminals L and N Check electrical supply Main terminal fuse Replace fuse Display Replace PCB illuminated Check wiring PCB - X1 connector terminals 1,2 Is there 230V at: Pump If pump jammed, release Replace pump...
  • Page 50 16.0 FAULT FINDING Temperature sensors faulty. Cold resistance approximately 10kΩ @ 25° C (DHW and CH sensors) Replace sensor 20kΩ @ 25° C (Flue sensor) (resistance reduces with increase in temp.) Check and correct the connection of the tube between the venturi and gas valve Gas at burner Ensure gas is on and purged...
  • Page 51 16.0 FAULT FINDING 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.
  • Page 52: Notes

    17.0 NOTES Publication No. 5116282...
  • Page 53 17.0 NOTES Publication No. 5116282...
  • Page 54 5 1 1 6 2 8 2 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...
  • Page 55: Service Interval Record

    SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate 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.
  • Page 56 B A X I P O T T E R T O N A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP After Sales Service 08706 017 017 Technical Enquiries 08706 049 049 Website www.potterton.co.uk 924.177.2 company...
  • Page 57 Gold Combi HE User’s Guide and Range Important Warranty Information This is a Wall Mounted Powered Flue Condensing Combination Boiler Gas Fired Central Heating Unit. The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency) Regulations 1993 N 3083”...
  • Page 58 Warranty heateam the service division of Baxi Potterton provide a 3 year free warranty for your peace of mind. Once your boiler is registered with us and in the unlikely event your boiler develops a fault and your installer is unable to assist, heateam will provide a free service to you provided the boiler is under 3 years old.
  • Page 59 Instructions on how to use your programmer and other heating controls should have been supplied with the items. Baxi Potterton also produce a guide ‘How to get the best out of your NEW Central Heating System’. Telephone our Literature Hotline on...
  • Page 60 Fault Indication 1. If a fault occurs on the boiler an error code may be shown on the facia display. Reset 2. The codes are either two or three digit, preceded by the letter 'E'. For example, code E133 GRASSLIN will be displayed by 'E1' alternating with '33'.
  • Page 61 Temperature Control 1. Central Heating: The central heating hot water flow temperature can be adjusted between 25° C minimum and 80° C maximum. 2. Turn the control knob clockwise to increase the temperature (Fig. 10). As the control knob is turned the selected temperature is displayed for approximately 4 seconds.
  • Page 62 Central Heating System Pressure Pressure Gauge 1. The water pressure in the central heating system is indicated by the pressure gauge. 2. With the system cold and the boiler not operating the pressure should be at least 0.5 bar. During operation the pressure should not exceed 2.5 bar, and will normally be between 1.0 and 2.0 Fig.
  • Page 63 Our Baxi Potterton trained heating experts will quickly get your heating and hot water working again. If your boiler is out of its free 3 year period, heateam can provide a competitive fixed price repair rate including parts, labour and VAT.
  • Page 64 Setting the Timer The Electro-Mechanical Timer allows the central Time Pointer heating system to be set every 15 minutes. Using the three position switch the timer will allow Constant either constant operation, timed operation or central heating off. Timed Move the switch button by sliding to the desired position.
  • Page 65 For your Safety 5mm Min 450mm 5mm Min This appliance must have been installed in accordance with the manufacturer’s instructions and the regulations in force. Any modification that may interfere with the 200mm Min normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty.
  • Page 66 In the unlikely event you have a problem with your boiler please check the following. 1. Is the electricity supply to your boiler switched on and the selector switch set to Central Heating and Hot Water? If so the Green ‘Power On’ neon will be on. No Heating/Hot Water 2.
  • Page 67 Warning ! If you smell gas Turn off the gas supply at the meter and call your gas supplier immediately. It is possible to isolate the boiler and at the isolating valve (Fig. 19). In GB, Transco operate a 24 hour emergency service and the telephone number will be listed in your telephone directory.
  • Page 68 Please complete the boxes below Baxi Potterton providing a free warranty service within 3 years of installation of your boiler. If your installer is Serial Number unable to rectify your boiler fault, by contacting one of our friendly advisors we can arrange an engineer if required.

This manual is also suitable for:

Gold 33 heGold 28 he

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