Potterton Gold Combi 24 HE A, Installation & Service Instructions Manual

Page 1: ...Ltd 2012 Installation Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Gold HE A Range Condensing Combination Boiler You can rely on ...

Page 2: ...ellings Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations Baxi Heating UK Ltd 2012 All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means or stored in any ret...

Page 3: ...elevant LABC You must ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www gassaferegister co uk within 10 days If you notify via the Gas Safe Register the register will issue the Building Regulations certificate on members behalf Complete the Benchmark Checklist Instal...

Page 4: ...iven reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent Person and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation All systems must be thoroughly flushed and treat...

Page 5: ...s clear and unobstructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep your back straight bend your knees Don t twist move your feet avoid bending forwards and sideways and keep the load as close to your body as possible Where possible transport the boiler using a sack ...

Page 6: ... Fixings 11 6 0 System Details 12 7 0 Site Requirements 15 8 0 Flue Options 19 9 0 Plume Displacement 24 10 0 Installation 28 11 0 Commissioning 34 12 0 Completion 37 13 0 Servicing 38 14 0 Changing Components 40 15 0 Setting the Gas Valve 49 16 0 Electrical 50 17 0 Short Parts List 51 18 0 Fault Finding 52 Benchmark Checklist 58 Section Page ...

Page 7: ...gives details of the model serial number and Gas Council number and is situated on the inner door panel It is visible when the case front panel is removed Fig 1 7 The boiler model name and serial number are also shown on the information label on the rear or the lower door panel This is for user reference 8 The boiler is intended to be installed in residential commercial light industrial E M C envi...

Page 8: ...te Trap 13 Flame Sensing Electrode 14 Spark Electrode 15 Primary Heat Exchanger 16 Fan Assembly 17 On Off Reset Selector Switch 18 Central Heating Temperature Control 19 Hot Water Temperature Control 20 Venturi 21 Air Gas Collector 22 Combustion Box Cover Burner 23 Igniter 24 Burner On Light 25 Central Heating Mode Light 26 Domestic Hot Water Mode Light 27 Display 28 Integral Timer 13 17 18 19 8 R...

Page 9: ... the boiler is isolated The boiler will not operate and the integral timer will require resetting once the selector switch is set to either Position i or Position ii 3 3 Frost Protection Mode 1 The frost protection mode is integral to the appliance and functions only with the selector switch see Section 2 1 in the domestic hot water and central heating position If the system temperature falls belo...

Page 10: ...put CH Net Max Min 24 model kW 20 5 7 28 model kW 24 7 9 33 model kW 28 9 9 7 Heat Output CH Non Condensing Max Min 24 model kW 20 6 8 28 model kW 24 8 7 33 model kW 28 9 4 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 155W 24 28 model 160W 33 model Electrical Protection IPX0D Internal Fuse Rating F2L Appliance Category CAT I 2H Inlet Pressure Natur...

Page 11: ... Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 65 mm 65 mm 65 mm 65 mm 65 mm 32 5 mm Condensate Drain Tap Rail 360 Orientation Flue Ø 100mm D C B A E G F At least 1 5 H 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 J 270mm J ...

Page 12: ... components 3 All systems must be thoroughly drained and flushed out using for example Sentinel X300 or X400 or Fernox F3 They should be used following the flushing agent manufacturer s instructions 4 System additives corrosion inhibitors and flushing agents descalers should comply to BS7593 requirements e g Sentinel X100 and Fernox MB 1 which should be used following the inhibitor manufacturer s ...

Page 13: ...vessel is suitable for correct operation for system capacities up to 125 litres 24 28 models 155 litres 33 models For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt 1 For IE the current edition of I S 813 Domestic Gas Installations 6 7 Safety Pressure Relief Valve Fig 6 1 The pressure relief valve is set at 3 bar therefore all pipework fittings e...

Page 14: ...eatment device already fitted to the wholesome water supply connected to the boiler domestic hot water DHW inlet supply then a suitable expansion device may be required 5 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 Th...

Page 15: ...ng Regulations and Building Regulations In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing This is the MINIMUM...

Page 16: ...the current edition of ETCI rules 2 The mains supply is 230V 50Hz fused at 3A NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Connection may be via a fused double pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only 7 6 Bath Shower Rooms 1 If the boiler is instal...

Page 17: ...diameter and must be supported using suitably spaced clips of the correct design to prevent sagging 6 It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres 7 Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe 8 External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external us...

Page 18: ... emptied then back pressure may force water out of the boiler trap and cause appliance lockout Boiler 2 5 Minimum fall iii Termination to a drain or gully Boiler 500mm min 2 5 Minimum fall iv Termination to a purpose made soakaway Holes in the soak away must face away from the building 50mm per metre of pipe run 50mm per metre of pipe run Further specific requirements for soakaway design are refer...

Page 19: ...ce Heating Element is NOT a substitute for correct installation of the condensate drain ALL requirements in this section must still be adhered to Boiler vi pumped into an external soil vent pipe 2 5 Minimum fall 50mm per metre of pipe run Condensate Pump Unheated Location e g Garage Basement or similar heated Boiler 2 5 Minimum fall 50mm per metre of pipe run Pipe must terminate above water level ...

Page 20: ...pening Window or Door 150mm MIN IMPORTANT If fitting a Plume Displacement Flue Kit the air inlet must be a minimum of 150mm from any opening windows or doors see Section 9 0 Plume Displacement Kit Air Inlet Fig 18a Terminal Position with Minimum Distance Fig 18 mm A1 Directly below an opening air brick opening windows etc 300 B1 Above an opening air brick opening window etc 300 C1 Horizontally to ...

Page 21: ...00 80 125 Horizontal Concentric 10 metres 20 metres 4 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 135 bend 0 5 metres 93 bend 1 0 metres Twin Flue Pipe 135 bend 0 25 metres 91 5 bend 0 50 metres 4 The elbow connected to the boiler adaptor is not included in any equivalent length calculations 5 The illustrations oppo...

Page 22: ...n of the flue length If further elbows are required the flue length must be reduced by the following amounts 1 metre for each 91 5 bend 0 5 metre for each 135 bend 8 2 Twin Vertical Flue Systems 1 Maximum permissible equivalent flue lengths are 60 100 80 125 Vertical Concentric 10 metres 20 metres Vertical Twin Pipe 15 metres 2 Any additional in line bends in the flue system must be taken into con...

Page 23: ... pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend 2 pair 135 5111086 J Vertical Flue Boiler Adaptor Kit 720089801 H Vertical Flue Adaptor 5111084 W Pipe Support pair 80mm 5111081 Y Flue Termination Kit horizontal termination 80mm 5120172 Z Single Terminal 80mm 5121791 Q Adaptor 60 80 5121792 T Pitched Roof Terminal 25 45 5106164 FLUE GROUP G Concentric Flue System 80 125mm diameter A4 H...

Page 24: ... adaptor in the boiler adaptor making sure that it is pushed down as far as possible 2 Ensure that the air flue ducts are connected correctly and that they are adequately supported at least once every metre using the available pipe supports 3 Ensure that all joints and elbows are fully engaged and cannot become disconnected during operation Flue Duct Connection Boiler Adaptor Air Duct Connection ...

Page 25: ...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 8 7 Flue Dimensions The standard horizontal telescopic flue kit allows for lengths between 100mm and 685mm from elbow to terminal Fig 19 The maximum permissible equivalent flue length is 10 metres 60 100 system 20 metres 80...

Page 26: ... or increase with the addition of extensions the length of either or both the 60 100 concentric and 60Ø exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length of the concentric flue is 100mm when measured from the edge of the flue elbow IMPORTANT The maximum equivalent length of concentric flue is 8 metres Additional b...

Page 27: ... 60Ø exhaust and any extensions or additional bends Example 1 Not Permissible If for instance a concentric length of 5 metres was required and the 60Ø exhaust needed to be 6 metres the graph shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths OK Where both lengths have been determined they can be applied to th...

Page 28: ... 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 9 The 60Ø exhaust can now be fitted Slide the adaptor over the plain end of the 60Ø exhaust Fig 22 and engage the exhaust in the terminal S...

Page 29: ...the extension at 30mm as shown in two positions directly opposite each other Fig 36 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure using two of the screws supplied 21 The remaining screw must be used to secure the adaptor to the concentric terminal 22 When the plume outlet is positioned under a balcony or other projection Fig 37 it must protrude at least 200mm it is ...

Page 30: ... slots 4 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 41 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 116mm 7 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using the fixing screws 8 Using a spirit level ensure that the plate...

Page 31: ...connect them to the central heating flow and return taps and the cold inlet tap The system can now be filled by opening the cold inlet supply and stop valves 8 If desired a suitable gauge can be connected to one of the taps so that the system may be accurately pressurised 9 All joints fittings and system components can now be examined for soundness at operating pressure 10 The system can be flushe...

Page 32: ...plied 3 The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside discharge point IMPORTANT Make all soldered joints before connecting to the ...

Page 33: ...s angled at 93 degrees to ensure a fall back to the boiler 3 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 51 4 To dimension X add 50mm This dimension to be known as Y IMPORTANT Check all dimensions before cutting 5 Mark dimension Y on the flue as shown Fig 52 Carefully cut the waste material from the flue ensuring that the ducts are square and ...

Page 34: ...ect boiler operation and prevent water entering the flue 11 Make good between the wall and air duct outside the building 12 Fit the flue trim if required and if necessary fit a terminal guard see Section 8 8 8 9 CONCENTRIC VERTICAL FLUE 13 Once the length of the vertical concentric extension has been determined mark and carefully cut off the excess material The cut end MUST be square and free of b...

Page 35: ...ing connected as in Fig 61 6 Remove the link between terminals 1 2 The 230V supply at terminal 2 must be connected to the thermostat The switched output from the thermostat must be connected to terminal 1 Figs 60 61 If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Figs 60 61 7 Ensure that the external control input cable s have sufficient slack to allow th...

Page 36: ... on and purge according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 10 Test for gas tightness 11 Hinge the facia panel upwards and refit the case front panel Tighten the securing screws IMPORTANT The combustion for this appliance has been checked adjusted and preset at the factory for operation on the gas type specified on the appliance data plate No measurement of the combustion...

Page 37: ...ances in the property working Measure the Gas Rate 8 With any other appliances pilot lights turned OFF the gas rate can be measured It should be between 24 model 2 6m3 h 28 model 3 1m3 h 33 model 3 6 m3 h 9 The Calibration Function is active for 20 minutes unless the maximum CH temperature is exceeded 10 The function can be disabled at any time by turning the DHW temperature knob 11 Carefully read...

Page 38: ...Off Bottom position No central heating Domestic hot water will operate on demand To set the time of day Turn the timer outer bezel clockwise to align the pointer with the correct time to the nearest 15 minutes ensuring that A M P M is considered Do not at any time attempt to turn the bezel anti clockwise To set the timed heating program Decide which times of the day the central heating is required...

Page 39: ...e appliance and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the B...

Page 40: ...requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Check the Combustion Performance CO CO2 ratio 4 Set the boiler to operate at maximum rate ...

Page 41: ... Initially check the cold water inlet tap filter 15 Turn the tap off and draw off from a hot tap Undo the blanking cap and remove the threaded bush Fig 78 16 Extract the filter and rinse thoroughly in clean water Reassemble and check the flow If required clean the restricter filter as described below 17 Pull off the Hall Effect sensor Undo the restricter from the inlet return manifold Fig 79 18 Ri...

Page 42: ...iter Fig 80 1 Disconnect the igniter feed plug and the electrode leads noting their positions 2 Undo the screw securing the bracket to the boiler 3 Remove the igniter and transfer the bracket to the new component 4 Reassemble in reverse order 14 2 Spark and Sensing Electrodes Fig 81 1 Disconnect the electrode leads noting their positions 2 Remove the retaining screws securing each of the electrode...

Page 43: ...securing the fan to the venturi and fit the new fan replacing the seal if necessary 6 Examine the burner gasket and replace if necessary 7 Reassemble in reverse order ensuring that the injector is in place and the sensing pipe is connected to the fan 14 4 Venturi Fig 82 1 Remove the collector and fan assembly as described in section 14 3 2 Extract the injector from the venturi 3 Undo the screws se...

Page 44: ...s noting their positions Also remove the electrodes as described in section 14 2 2 Undo the screws securing the collector to the venturi and the nuts holding the cover to the heat exchanger Draw the collector and cover assembly away 3 Remove the cover insulation piece 4 Fit the new insulation carefully over the burner and align it with the slots for the electrodes 5 If the rear insulation requires...

Page 45: ...Reassemble in reverse order The component is not polarised either wire will fit each terminal 14 10 Central Heating Temperature Sensor NTC Fig 88 1 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way 14 11 Safety Thermostat Fig 88 1 Pull the plug off the thermostat 2 Remove...

Page 46: ...ing the body to the pipe and manifold and draw the pump forwards 3 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 4 Unscrew the automatic air vent from the pump body 5 Connect the wiring to the new pump Examine the O ring seals on the return pipe and ma...

Page 47: ...he electrical plug from the sensor 3 Connect the plug to the new sensor Carefully fit the new sensor to the hydraulic assembly ensuring it is fully down 14 19 Pressure Relief Valve Fig 97 1 Drain the boiler primary circuit 2 Disconnect the discharge pipe from the valve Using a suitable hexagon key undo the grub screw sufficiently to release the valve 3 Note the orientation of the valve rotate it a...

Page 48: ...t hand location stud is offset towards the centre more than the right hand one 7 Reassemble in reverse order 14 21 Diverter Valve Motor Unit Assembly Fig 99 1 To replace the motor unit disconnect the multi pin plug 2 Pull off the retaining clip and remove the motor unit 3 The motor unit can now be replaced or the valve assembly removed 4 Drain the primary circuit and draw off any hot water once th...

Page 49: ... 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 14 23 Selector Switch Fig 102 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hinge pi...

Page 50: ... at the gas air inlet and the gas valve Remove the pipe taking care not to lose the sealing washers Remove the valve 5 Reassemble in reverse order ensuring that all seals are in place and the injector is fitted NOTE To assist the boiler to light prior to final setting use a suitable hexagon key to wind out the Throttle adjustment screw until it is flush with the valve body then turn the screw 4 fu...

Page 51: ...t the analyser probe and allow sufficient time for the reading to settle Fig 111 The CO2 should be 8 7 0 2 8 It is possible to alter the CO2 by adjustment of the gas valve Remove the plastic cover from the Throttle Adjustment Screw At maximum rate the Throttle Adjustment Screw should be turned using a suitable hexagon key until the correct reading is obtained Fig 112 Turning clockwise will reduce ...

Page 52: ...eating NTC Sensor Fan GasValve Overheat Stat Flame Sensing Electrode Pump Flue Sensor X400 X401 g g b b r r b b b b b br bk g b br g y b br b br br b b b br br br b b br r bk r bk Water Pressure Switch Spark Generator Ignition Electrode 9 8 7 6 5 4 3 2 1 9 10 8 7 6 5 4 3 2 1 Hall Effect Sensor r w b w r bk bk r w DiverterValve Timer 1 2 3 4 1 2 3 4 bk br bk b N L w g 1 4 2 5 3 1 2 a b Link bk b g ...

Page 53: ...s Valve 720301001 404 Hall Effect Sensor 5114767 306 Burner 24 28 5122149 Burner 33 5114697 419 Water Pressure Switch 5114748 400 Plate Heat Exchanger 24 28 248048 Plate Heat Exchanger 33 5114708 415 Pump 248042 421 NTC Sensor 5114725 420 Overheat Thermostat 5114729 504 Pressure Gauge 248090 503 PCB 24 5121862 PCB 28 720043401 PCB 33 720795201 302 Flue Safety NTC 5114747 306 426 315 316 311 422 40...

Page 54: ...133 will be displayed by E1 alternating with 33 E50 is shown as E then 50 E20 E28 E50 indicate faulty or incorrect components E110 shows overheat of the primary water and E130 overheat of the flue system E119 is displayed when the primary water pressure is less than 0 5 bar E133 indicates that the gas supply has been interrupted ignition has failed or the flame has not been detected E125 is displa...

Page 55: ...ror 133 flashing Burner does not stay alights after 5 seconds Error 133 flashing Go to section I Operation sequence successful If the error 110 is still flashing Go to section J Fan runs at correct speed YES YES NO NO NO YES YES YES YES YES YES YES YES NO YES YES YES YES NO NO NO NO NO Burner output modulates to maintain the temperature set Burner goes out Go to section C Ensure controls are set t...

Page 56: ...hts after 5 seconds Error 133 flashing Go to section I Operation sequence successful Turn the selector switch to reset position for 5 seconds If the error 110 is still flashing Go to section J Fan runs at correct speed YES YES NO NO NO YES YES YES YES YES YES YES YES NO YES YES YES YES NO NO NO NO NO Burner output modulates to maintain the temperature set DHW flow sensor senses no flow Burner goes...

Page 57: ...onnector terminals 3 4 Replace PCB 2 NO Change pump supply cable YES B CH system pressure less than 0 5 bar Re pressurise system 1 YES Check the tap of the automatic air vent is opened Open the automatic air vent 2 NO C 1 NO YES Fan connections correct at fan PCB X2 connector is 230V AC across terminals 5 7 Fan jammed or faulty winding Replace PCB Replace fan YES D If pump jammed release NO NO Rep...

Page 58: ...d lead 2 Electrode connection 3 Spark gap and position YES NO Replace igniter YES H YES 1 Ensure that the Hall Effect Sensor is in position Check the connection between the PCB X400 connector terminals 3 6 7 and the electronic sensor Check the voltage between red wire and blue wire is more than 5V DC NO Replace PCB Check and correct the connection of the tube between the venturi and gas valve Repl...

Page 59: ...ostat operated or faulty i e continuity across thermostat terminals Allow to cool Continuity across thermostat terminals more than 1 5 ohm J L M Is there 230V at Motor 3 way valve Replace motor 3 way valve 1 YES PCB X3 connector terminals 5 6 central heating mode 5 7 domestic hot water mode Replace PCB 2 NO Change pump supply cable YES Fan connections correct at fan PCB X401 connector terminals 5 ...

Page 60: ...60 19 0 Pages for Notes Baxi Heating UK Ltd 2012 ...

Page 61: ...61 19 0 Pages for Notes Baxi Heating UK Ltd 2012 ...

Page 62: ...em cleaner was used Gas Rate Burner Operating Pressure if applicable Central Heating Flow Temperature Central Heating Return Temperature Gas Rate Burner Operating Pressure at maximum rate Cold Water Inlet Temperature Hot Water has been checked at all outlets If required by the manufacturer record the following The heating and hot water system complies with the appropriate Building Regulations The ...

Page 63: ...er Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Operative ID No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments S...

Page 64: ... 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 POTTERTON A Trading Division of Baxi Heating UK Ltd 3879156 Brooks House Coventry Road Warwick CV34 4LL After Sales Service 0844 871 1560 Technical Enquiries 0844 871 1555 Website www potterton co uk e oe ...