Potterton Gold Combi 24, Installation And Service Manual

Page 1: ... Combi Installation and Service Manual Condensing Combination Boiler 24 28 33 en United Kingdom These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping ...

Page 2: ...llings 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 2016 All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means or stored in any retr...

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: ...he 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 treated with inhibitor see section 6 2 The boiler meets the requirements of Statutory Instrument The Boiler Efficiency Regulations 1993 No 3083 and is deemed to meet the requirements o...

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: ...ns and Fixings 12 6 0 System Details 13 7 0 Site Requirements 16 8 0 Flue Options 21 9 0 Installation 23 10 0 Commissioning 29 11 0 Completion 32 12 0 Servicing 33 13 0 Changing Components 35 14 0 Setting the Gas Valve 44 15 0 Electrical 45 16 0 Short Parts List 46 17 0 Fault Finding 47 18 0 Notes 53 Benchmark Checklist 54 Section Page ...

Page 7: ... case front panel is removed Fig 1 6 The boiler model name and serial number are also shown on the information label on the back of the facia door This is for user reference 7 The boiler is intended to be installed in residential domestic environments on a governed meter supply only 8 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit part ...

Page 8: ...ng System Pressure Gauge 9 PCB 10 Control Box 11 3 Way Valve Assembly 12 Condensate 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 Li...

Page 9: ...olated 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 below 5 C then the bo...

Page 10: ...3 125 W Electrical Protection IPX5D Internal Fuse Rating F2L Appliance Category CAT I 2H Inlet Pressure Natural Gas G20 mbar 20 Injector Natural Gas G20 7 5mm 24 28 model 12mm 33 model Appliance Type C13 C33 C53 Heat Output CH Pnc Condensing Max Min 24 model kW 21 7 4 28 model kW 25 9 9 5 33 model kW 30 3 10 2 Heat Output DHW Max 24 model kW 24 28 model kW 28 33 model kW 33 Max Gas Rate Natural Ga...

Page 11: ...ower consumption Pign kW Annual energy consumption QHE kWh GJ Sound power level indoors LWA dB Emissions of nitrogen oxides NOX Daily electricity consumption Domestic hot water parameters Declared load profile Water heating energy efficiency Qelec kWh Annual electricity consumption AEC kWh Šwh Daily fuel consumption Qfuel kWh Annual fuel consumption AFC GJ 1 Low temperature means for condensing bo...

Page 12: ...15mm Heating 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 Tube Ø 100mm D C B A E G F At Least 1 5 H NOTE There must be no part of the air duct white tube visible outside the property after installation The flue seal should fit neatly and effect a good seal For full detail refer to Section 9 7...

Page 13: ...lushed out using for example Sentinel X300 or X400 or Fernox F3 They should be used following the flushing agent manufacturer s instructions 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 instructions Full instructions are supplied with the product...

Page 14: ...Expansion Vessel Central Heating only 1 The appliance expansion vessel is pre charged to 0 5 bar Therefore the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres 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 Installatio...

Page 15: ...he 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 The manufacturer of any outlet fitti...

Page 16: ... Wiring 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 MI...

Page 17: ... GB this is the current I E E Wiring Regulations In IE reference should be made to 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 ...

Page 18: ...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 19: ...orrect installation of the condensate drain ALL requirements in this section must still be adhered to 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 ar...

Page 20: ...the diagram below Opening 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 Plume Displacement Kit Air Inlet Fig 12 Terminal Position with Minimum Distance Fig 13 mm A1 Directly below an opening air brick opening windows etc 300 B1 Above an opening air brick opening window etc 300 C1 Horizontally t...

Page 21: ...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 opposite show examples of permissible flue systems NOTE Flue length is measured from point X to Y as shown IMPORTANT SUPPORT All flue systems MUST be securely suppo...

Page 22: ...ds as shown or up to 45 either way from vertical Secure the deflector to the terminal with screws provided 8 6 Flue Accessories Fig 15a 1 For full details of Flue Accessories elbows extensions clamps etc refer to the Flue Installation Guide supplied in the literature pack Guidance Notes Flue Accessories Fitting Guide en United Kingdom Please leave these instructions with the Installation and Servi...

Page 23: ...irements see Section 7 0 position the fixing template on the wall ensuring it is level both horizontally and vertically 5 Mark the position of the two most suitable fixing slots for the wall plate and boiler lower fixing holes It is preferable to use the vertical fixing slots 6 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 18 7 If required mark the...

Page 24: ...onnect 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 flushed...

Page 25: ...ischarge pipe in the vicinity of the boiler Make up as much of the pipework as is practical including the discharge pipe supplied 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...

Page 26: ...ow This dimension will be known as X Fig 23 5 If the distance from the flue elbow to the outside face of the wall X in Fig 23 is less than 250mm the Connection Assembly can be discarded and the Terminal Assembly fitted directly into the elbow 6 In instances where the dimension X Fig 23 is between 250mm and 315mm it will be necessary to shorten the Terminal Assembly by careful cutting to accommodat...

Page 27: ...ally 13 It is recommended that if the internal trim is being used it is first fitted over the elbow to allow access to the securing screws and then manoeuvred into place against the wall 14 Draw the flue back through the wall and engage it in the elbow It may be necessary to lubricate to ease assembly of the elbow and flue Fig 28 15 Ensure that the terminal is positioned with the slots to the bott...

Page 28: ...nal integral timer 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 Fig 32 If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Fig 32 7 Ensure that the external control input cable s have sufficient slack to allow the control box to...

Page 29: ...nel Tighten the securing screws 12 Having checked That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals Proceed to put the boiler into operation as follows 13 The Combustion Check procedure as shown by the chart in 10 2 is mandatory The method of setting the ...

Page 30: ...nal flue seals door case seals Replace any seals that appear unsound Is CO 350ppm and CO CO2 ratio 0 004 TURN APPLIANCE OFF Call 0344 871 1525 for advice The appliance MUST NOT be commissioned until all problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with the GSIUR Note Check record the CO combusti...

Page 31: ...ained with all other gas appliances 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 temp...

Page 32: ...gular 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 Benchmark Commissioning Checklist 5 Hand over the Users Operating Installation and Servicing Instructions giving advice on the necessity of regular servicing Facia Panel Case Fr...

Page 33: ...ments 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 as desc...

Page 34: ... it may be necessary to clean the filter 14 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 49 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 ...

Page 35: ...acket to the new component 4 Reassemble in reverse order 13 2 Spark and Sensing Electrodes Fig 52 1 Disconnect the electrode leads noting their positions 2 Remove the retaining screws securing each of the electrodes to the combustion box cover and remove the electrodes 3 Check the condition of the sealing gasket and replace if necessary Reassemble in reverse order 13 3 Air Pressure Switch Fig 52a ...

Page 36: ... in the venturi 5 Undo the screws 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 13 5 Venturi Fig 54 1 Remove the collector air pressure switch and fan assembly as described in section 13 4 2 Extr...

Page 37: ...e the electrodes as described in section 13 2 2 Undo the screws securing the collector to the venturi and the nuts holding the cover to the heat exchanger Allow the air pressure switch to rest on the air box lower panel 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 I...

Page 38: ... Reassemble in reverse order The component is not polarised either wire will fit each terminal 13 11 Central Heating Temperature Sensor NTC Fig 59 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 13 12 Safety Thermostat Fig 59 1 Pull the plug off the thermostat 2 Remov...

Page 39: ...dfos Fig 61 1 Drain the boiler primary circuit and unscrew the automatic air vent from the pump body 2 Examine the O ring seal replacing if necessary and fit it to the new automatic air vent 3 Reassemble in reverse order 13 16 Automatic Air Vent Wilo Fig 62 1 Drain the boiler primary circuit and remove the U clip securing the automatic air vent to the pump body 2 Pull the vent upwards away from th...

Page 40: ...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 13 19 Pressure Relief Valve Fig 66 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 41: ...t hand location stud is offset towards the centre more than the right hand one 7 Reassemble in reverse order 13 21 Diverter Valve Motor Unit Assembly Fig 68 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 42: ...ndo the screws securing the control box cover and release the cover retaining barbs from their slots 2 Note the position of all plugs and wires on the P C B and disconnect them Undo the securing screws and remove the P C B 3 Reassemble in reverse order 13 24 Selector Switch Fig 69 70 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo the screws sec...

Page 43: ... 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 full turns clockwise Fig 72 If the boiler will not light or the correct CO2 cannot be achieved call Baxi Customer Support 0344 871 1525 13 26 Expansion Vessel Fig 73 ...

Page 44: ... the plug from the flue sampling test point Insert the analyser probe and allow sufficient time for the reading to settle Fig 80 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...

Page 45: ... Electrode Pump Grundfos Flue Sensor X400 X401 g g b b r r b b b b b b br bk g b br g y b br b br br b b 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 1 2 3 4 1 2 3 4 bk br bk b N L w g or w 1 4 2 5 3 1 2 a b Link bk b g y br Mains Input Cable br b b br Pump PCB Timer where...

Page 46: ... Hall Effect Sensor 5114767 306 Burner 24 5122149 Burner 28 5122149 Burner 33 5114697 419 Water Pressure Switch 5114748 400 Plate Heat Exchanger 248048 415 Pump 7654033 421 NTC Sensor 5114725 420 Overheat Thermostat 5114729 504 Pressure Gauge 5118385 503 PCB 24 5121862 PCB 28 720043401 PCB 33 720795201 517 Pump PCB 7222704 302 Flue Thermostat 5114747 505a Air Pressure Switch 7648326 306 426 315 31...

Page 47: ... 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 displayed in either of two situations i If within 15 seconds of the burner lighting the boiler temperature has not changed by 1 ii If within 10 minutes of the burner lighting the boiler temperature...

Page 48: ...ner 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 to demand and verify ...

Page 49: ...ds 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 out Go to sectio...

Page 50: ...t 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 NO Replace water pressure switch Check connection water pressure switch terminal COM NO and PCB connector X400 terminals 3 4 YES Is there 230V at X3 Connection Pump PCB 1 NO YES B Check incoming wiring X2 ...

Page 51: ...s more than 5V DC NO Replace PCB Check and correct the connection of the tube between the venturi and gas valve Replace Hall Effect Sensor YES 1 2 Voltage at PCB X2 connector is at least 100V DC across terminals 2 5 Note from multimeter connect common to 2 volts to 5 Check wiring 7 5 1 4 0 5 10 1 Spark Ignition Electrode Sensing Electrode Electrode Position Viewing Window Burner Temperature sensor...

Page 52: ...w 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 6 7 8 1 YES Replace fan Temperature sensors faulty Cold resistance appro...

Page 53: ...53 Baxi Heating UK Ltd 2016 18 0 Notes ...

Page 54: ...quired Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler interlock Provided ALL SYSTEMS s instructions Yes What system cleaner was used What inhibitor was used Quantity litres Yes No CENTRAL HEATING MODE measure and record Gas rate m hr OR ft hr Burner operating pressure if applicable mbar OR Gas inlet pressure mbar C Central heating return temp...

Page 55: ...e Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 06 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 07 Date Engineer name Company name Telephone No Gas safe register No Record At m...

Page 56: ...erms and conditions visit www baxi co uk terms Failure to adhere to terms and conditions will void your manufacturer s warranty Baxi Brooks House Coventry Road Warwick CV34 4LL Please ensure the boiler is installed in accordance with these installation instructions and that you adhere to the Building Regulations e oe All descriptions and illustrations provided in this document have been carefully ...