Potterton Gold FSB 30 HE, Installation & Service Instructions Manual

Page 1: ... Installation Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Promax FSB 30 HE Floor Standing Fanned Flue Condensing Boiler You can rely on ...

Page 2: ...ilable from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information ISO 9001 FM 00866 Building Regulations and the Benchmark Commissioning Checklist Building Regulations England Wales require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department From 1 April 2005 th...

Page 3: ... relevant 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 Inst...

Page 4: ...ons and the regulations in force Read the instructions fully before installing or using the appliance In GB this must be carried out by a competent person as stated in the Gas Safety Installation Use Regulations Definition of competence A person who works for a Gas Safe registered company and holding current certificates in the relevant ACS modules is deemed competent In IE this must be carried ou...

Page 5: ...ngs 10 6 0 System Details 11 7 0 Site Requirements 15 8 0 Flue Options 20 9 0 Plume Displacement 25 10 0 Installation 29 11 0 Electrical 34 12 0 Commissioning the Boiler 36 13 0 Completion 38 14 0 Servicing the Boiler 39 15 0 Changing Components 42 16 0 Short Parts List 49 17 0 Fault Finding 50 Benchmark Checklist 58 Section Page Contents ...

Page 6: ...ues such as the standard horizontal flue kit part no 236921 1 2 Important Information Man made mineral fibre Some component parts of this boiler insulation pads gaskets and rope seals are manufactured from man made mineral fibre Prolonged or excessive exposure to this material may result in some irritation to the eyes skin or respiratory tract It is advisable to wear gloves when handling these ite...

Page 7: ...3 4 5 6 7 9 8 10 11 15 14 12 13 16 Fig 4 Fig 3 Fig 5 2 2 110Ø Concentric Flues Optional Extras KIT PART No Standard Flue Kit 850mm inc elbow 236921 Extended Flue Kit 1 75M inc elbow 5111457 Flue Plume Deflector Kit 248167 Terminal Guard suitable for use with above 248484 FLUE EXTENSION KITS 110 70 Flue Extension 250mm 241692 Flue Extension 500mm 241694 Flue Extension 1000mm Use two kits for 2M etc...

Page 8: ...eby the gas rate to achieve optimum operation If the flow temperature is greater than the set point or the TRVs all shut down then fan post purge occurs 6 Fan Post Purge The fan is on while the spark generator and gas valve are off After 5 seconds if the TRVs are shut down then anti cycle occurs 7 Anti cycle The fan spark generator and gas valve are off 8 Ignition Lockout The fan spark generator a...

Page 9: ...ter 6 5mm Minimum Clearances For unventilated compartments see Section 7 2 Both Sides 5mm Above Casing 15mm Above Casing Under fixed worktop It is recommended that any worktop is removable 25mm Front For Servicing 500mm Front In Operation 5mm 0 10 20 30 40 20 40 60 80 100 120 140 160 180 200 220 Water Flow Rate litres min Pressure Drop mbar 8 17 25 33 42 50 58 66 75 83 91 Pressure Drop in wg Boile...

Page 10: ... 27 5mm to incorporate the 1 5 fall in the flue from the terminal to the elbow It is especially important to consider this when fitting the boiler under a work top The 1 5 fall provided by the elbow is to allow condensate to run back to the boiler for discharge through the condensate disposal system Flue length Y up to 1m 1m 2m 2m 3m 3m 4m Clearance X 27 5mm 55mm 82 5mm 110mm Tube Ø 110mm D C B A ...

Page 11: ...d an appropriate water treatment is applied To prevent this follow the guidelines given in BS 7593 Treatment of Water in Domestic Hot Water Central Heating Systems and the treatment manufacturers instructions 2 Treatment must involve the use of a proprietary cleanser such as Sentinel X300 or X400 or Fernox F3 and an inhibitor such as Sentinel X100 or Fernox MB 1 3 Full instructions are supplied wi...

Page 12: ...e boiler b The pump must be fitted on the flow c The pump must be fitted in accordance with the pump manufacturer s instructions d The open vent pipe must be taken up from a tee in a horizontal section of the flow pipe 2 For heads below 400mm then an alternative utilising a combined vent and feed pipe may be connected Fig 12 This must be a minimum of 22mm diameter It is recommended that an air sep...

Page 13: ... be provided to switch off the boiler when there is no demand for heating Y Plan Diverter Valve Cylinder Stat Room Stat Boiler Connection 4 Core Wire Pump Timer 230V 50Hz L N E L N CH on HW on HW off L N E S L N E b g y w o gr 1 C 2 P L System Control Wiring Centre g y S Plan Valve Cylinder Stat Room Stat Boiler Connection 4 Core Wire Pump Timer 230V 50Hz L N E L N CH on HW on L N E S L N E Motor ...

Page 14: ... supply pipe provided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment Your attention is drawn to for GB Guidance G24 2 and recommendation R...

Page 15: ...r shower it can only be fitted in Zone 3 Figs A B shows zone dimensions for a bathtub For other examples refer to the Current I E E Wiring Regulations Reference must be made to the relevant requirements In GB this is the current I E E 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 6 ...

Page 16: ...e that the pipework from the meter to the boiler is of adequate size If the boiler is further than 3 metres from the Gas Meter 22mm pipe should be used Do not use pipes of a smaller diameter than the boiler gas connection 7 5 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current I E E Wiring Regulations I...

Page 17: ...connect to 21 5mm overflow pipe is also supplied 4 The 10mm pipe can be routed to a maximum of 3 metres vertically and then discharge via gravity or be routed horizontally Fig A A combination of vertical and horizontal runs is permissible 5 The pipe must be supported either using suitably spaced clips or run within larger diameter pipe When using clips take care not to deform the pipe 6 When routi...

Page 18: ...eely without blockage or restriction of the pipe into the drain iv to a soakaway Fig F From Boiler Termination to an internal soil and vent pipe Termination via internal discharge branch e g sink waste downstream Sink Pipe must terminate above water level but below surrounding surface Pipe must terminate above water level but below surrounding surface Termination to a drain or gully Termination to...

Page 19: ...al position must ensure the safe and nuisance free dispersal of combustion products Fig 16a 300 min Terminal Assembly TopView Rear Flue Property Boundary Line NOTE The distance from a fanned draught boiler terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below unless the flue deflector kit is used see 7 8 6 opposite Table 2 Terminal Position with ...

Page 20: ...xamples 8 1 Horizontal Flue Systems Only a flue approved with the Potterton Promax FSB 30 HE Plus can be used Concentric The maximum equivalent lengths are 4m horizontal or vertical Their lengths exclude the standard elbow and flue terminal assembly horizontal and terminal assembly vertical Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths ar...

Page 21: ...assembly vertical Twin Flue The total maximum equivalent flue length is 150m NOTE Each 1m of flue duct should be calculated as 2m Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 135 bend 0 5 m 93 bend 1 0 m Twin Flue Pipe 135 bend air duct 1 3 m 135 bend flue duct 2 6 m 90 bend air duct 4 8 m 90 bend flue duct 9 6 m IMP...

Page 22: ...0mm 243014BAX T Vertical Flue Boiler Adaptor 5106888 S Flue Terminal Deflector 248167 FLUE GROUP P Twin Flue System 80mm diameter E Flue Extension pair 1000mm 246137 500mm 246136 250mm 246135 F Flue Bend pair 90 5121560 G Flue Bend 2 pair 135 5121561 J Vertical Flue Boiler Adaptor Kit 242757 W Pipe Support pair 80mm 5111081 FLUE GROUP B P Vertical Flue Kits K Vertical Flue Terminal 242802 L Pitche...

Page 23: ... Fix the vertical adaptor and gasket to the top panel with the previously removed screws 8 5 For Twin Flue Systems 1 Undo the screws securing the blanking plate to the boiler top panel Discard the plate 2 Fix both the air and flue adaptors with their gaskets onto the boiler top panel Secure with screws For Vertical Flues For Twin Flues Air Duct Adaptor Flue Duct Adaptor Gasket Gasket Blank Plate ...

Page 24: ...he collar of the flue locates securely with the flashing A mastic seal may be necessary From inside the roof adjust the flue to a vertical position and secure to the roof structure with the clamp supplied 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 ...

Page 25: ...oth the 70 110 concentric and 70Ø 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 boiler flue elbow There is a further 45mm engagement into the elbow IMPORTANT The maximum equivalent length of concentric flue is 4 metres Additional elbows may be ...

Page 26: ...issible If for instance a concentric length of 3 25 metres was required and the 70Ø exhaust needed to be 10 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 the graph to check that the installation is permissible For example ...

Page 27: ...o support the concentric assembly and any extensions and make good inside and outside Secure the flue trim to the wall 9 The 70Ø exhaust can now be fitted to the spigot at the terminal end 10 If it is necessary to shorten the 70Ø exhaust or any of the extensions the excess material must be cut from the plain end of the pipe 11 Determine the position of the 70Ø exhaust and mark on the wall a suitab...

Page 28: ...ust in an enclosed box but the air inlet and plume outlet MUST remain in free air 17 It is also possible to separate the plume outlet from the 93 elbow to allow the flue to be installed as shown in Fig H 18 When the plume outlet is positioned under a balcony or other projection Figs I J it must protrude at least 200mm it is not necessary to extend it further than this 200mm Min Fig H Fig I Fig J ...

Page 29: ...herefore some pipe movement will be evident even though a water tight seal has been achieved Excessive force could result in damage to the connection 3 Make all soldered joints before connecting the tails to the boiler to avoid damaging the O rings 4 Refit the pipe access panel 10 3 Making the Gas Connection 1 The connection to the boiler is a 15mm tail on the gas service cock The tail protrudes t...

Page 30: ... X from the terminal end as indicated in the diagram Fig 27 4 For side exit measure the distance from the edge of the boiler case to the inner face of the wall Fig 26 and to this dimension add the wall thickness 280mm This dimension to be known as Z i e Z case to wall wall thickness 280 5 Take the flue and mark off Z from the terminal end as indicated Fig 27 Before cutting check your dimensions 6 ...

Page 31: ...connection on top of the boiler Secure with the four screws supplied in the kit 12 Make good between the wall and air duct outside the building ensuring the 3 drop between the terminal and elbow 13 The flue trim should be fitted once the installation is complete and the flue secure Fig 30 Apply a suitable mastic to the inside of the trim and press against the wall finish making sure the brickwork ...

Page 32: ...If the boiler is fitted in an unheated location the entire length of condensate pipe should be treated as external and run within insulated larger diameter pipe 9 Ensure that the condensate can discharge freely without blockage or restriction of the pipe into the drain 10 Examples are shown of condensate pipe methods of termination i via an internal discharge branch e g sink waste Fig B ii to an i...

Page 33: ...system control wiring centre through the grommet in rear of the boiler and the grommet in the support bracket This will prevent damage to the cable s 4 Lay the cable through the cable clamp to gauge the length of wire required when it is connected to the 4 way terminal block 5 Connect the S L N and P L wires to the 4 way terminal block Fig 33 and refit the cable clamp Fig 31 INTEGRAL PROGRAMMER 6 ...

Page 34: ...e Condensate Trap Flow Overheat Thermostat Fan Overheat Thermostat g y r b r r Flow Thermistor 325Vdc DC Fan CH Flow Switch gy gy w g br PCB Earths not shown to aid clarity of diagram g y Electrical Filter CH Out DHW Out DHW Off Out Permanent Live Neutral Earth Switched Live Optional InternalTimer br b g y br b y v o Condensate Pump Condensate Over Level Switch Condensate Level Switch L N gy gy br...

Page 35: ...ue y Yellow 11 2 Illustrated Wiring Diagram GasValve Fan CondensateTrap CH Flow Switch Flow Thermistor Spark Electrode Flame Detection Electrode Main PCB N P L S L r r gy gy b br g w Flow Overheat Thermostat Fan Overheat Thermostat bk bk bk r bk w w op g y g y b Layout of PCB Pins g y o br g y Electrical Filter br g y b r w b br gy gy g y ...

Page 36: ...omplete the label supplied with the inhibitor and attach to the inside of the boiler case Detail of system treatment should be added for future reference 6 Turn the gas supply on and purge according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 7 Turn the gas service cock anticlockwise to the ON position and check for gas tightness up to the gas valve Fig 34 Turn the power to the b...

Page 37: ...ot lights turned OFF the gas rate can be measured It should be as shown in Section 4 0 Technical Data 5 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the boiler 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...

Page 38: ...essary to complete a Declaration of Conformity to indicate compliance to 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 13 3 Handover 1 Instruct the user in the operation of the boiler and system controls Hand over the User s Operating Installation and Servicing Instructions giving advice on the necessity of re...

Page 39: ...cuit and relevant seals as described in Section 14 2 The operational gas inlet pressure as described in Section 12 2 1 to 12 2 3 and the gas rate as described in 12 2 4 The combustion performance as described in Check the Combustion Performance 14 1 4 to 14 1 6 below 3 Competence to carry out Checking Combustion Performance B S 6798 Specification for Installation Maintenance of Gas Fired Boilers n...

Page 40: ...ads from the terminals Fig 40 5 Undo the four screws securing the combustion box door and remove the door Fig 41 6 Visually check for debris damage and clean or replace if necessary the following a Burner b Heat exchanger fins c Fan compartment Check also for condensate leaks d Insulation e Door seals Important Pay particular attention to the condition of the combustion box door seals f Electrodes...

Page 41: ...soft brush i Loosen the two screws retaining the heat exchanger support bracket and slide to the left to remove Fig 44 j Remove the four screws securing the heat exchanger combustion box base and withdraw the base k Lower the central insulation panel and check condition Fig 44 Replace the lower insulation pad if necessary l Ensure the heat exchanger fins are clear of any obstruction m Check condit...

Page 42: ... 1 Isolate the water circuit and drain the system as necessary A drain point is located on the heat exchanger manifold at the right hand side of the boiler Fig 45 to enable the heat exchanger to be drained 2 Place a tube on the drain point to drain water away from the electrics Turn anticlockwise to open Fig 45 3 After changing a component recommission the boiler where appropriate and check the in...

Page 43: ...e 3 Connect the condensate outlet pipe to the new pump using the new clip provided 4 With the new pump in place on the studs refit the trap discharge pipe ensuring the O ring is in place Reconnect the electrical plug 5 Neatly coil the excess condensate outlet pipe adjacent to the pump ensuring that it is not kinked or restricted 6 Check operation of the pump See Section 10 2 15 5 Condensate Pump L...

Page 44: ...nd securing screw and swing out the PCB housing Remove the PCB cover and disconnect the electrical plugs noting their positions 3 Remove the screw securing the PCB to the housing The PCB can be removed from the housing 4 Ensure that the two jumpers are fitted to the new PCB as shown Fig 49 5 Reconnect the plugs fit the new PCB to the housing and reassemble in reverse order PCB Housing Securing Scr...

Page 45: ...WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate system controls before access 1 Loosen the screw holding the injector pipe into the venturi 2 Remove the electrical connections to the fan and protection sensor on the fan 3 Remove the wing nuts securing the fan to the base of the combustion box 4 Lower the fan and remove 5 If changing the fan remove the screws securing the venturi and f...

Page 46: ...emove the valve 6 Remove the aluminium spacer and its gasket from the gas valve 7 Fit the aluminium spacer and its gasket to the new valve 8 Fit the new gas valve and reassemble in reverse order NOTE Check for gas tightness after replacing gas valve 9 Check the CO2 level If the level is greater than that quoted telephone the Technical Enquiries for further advice 15 11 Condensate Trap Fig 54 1 Dis...

Page 47: ...ction 13 1 paragraph 2 3 2 Remove all components in the base of the airbox 3 Undo the screws on the support bracket Remove the screws securing the flow switch and return connections and remove the connections Fig 57 4 Remove the screws securing the heat exchanger manifold and remove the manifold Fig 58 5 Ease the combustion box left hand side panel to clear the stud lift the heat exchanger assembl...

Page 48: ...changer and remove the lower insulation pad 6 Fit the new insulation pad and reassemble in reverse order 15 15 Heat Exchanger Upper Insulation Pad Fig 60 1 Remove all components in the base of the airbox 2 Remove the burner see section 13 10 3 Remove the heat exchanger see section 13 11 4 Remove the four bolts securing the combustion box base 5 Remove the combustion box base 6 Pull the central ins...

Page 49: ... Flow Switch 242459 C E06 060 Safety Thermostat Black 242235 D PCB 5129147 E Fan 5109925 F Gas Valve 241900 G E06 085 Viewing Window 242484 H Condensate Trap 5111714 I Electrodes Kit 5132366 J Burner Assy 5107430 K E06 097 Heat Exchanger Assy 242497 L Control Knob 5109996 M Condensate Pump 5117661 N Level Switch 5117591 O Over Level Switch 5117592 A B C E F G H I J K D L M N O ...

Page 50: ...g harness PCB Fault Replace PCB PCB Fault Replace PCB PCB Fault Replace PCB YES YES YES YES YES YES YES YES YES YES YES YES Go to Electrical Supply section of the fault finding instructions Go to Dry Fire section of the fault finding instructions Go to Overheat Lockout section of the fault finding instructions NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after...

Page 51: ...l block to PCB Check for short circuit on condensate pump fan gas valve Replace if shorted replace fuse YES NO Replace PCB YES YES NO NO ELECTRICAL SUPPLY 240V at B PCB fuse OK C Fuse B N S L Lights Off Off Off P L A D No Permanent Live to boiler Check Mains Fuse and System Wiring 240V at D Check S L wiring from terminal block to PCB YES NO NO 240V at A YES ...

Page 52: ... H Disconnect Flow Switch Inline connector With pump running is there continuity across flow switch Remove Blockage NO YES NO YES Pump or Pump Wiring fault Is there a blockage in the system YES Replace PCB Wires from inline connector to PCB faulty Remove flow switch from boiler Is there a physical blockage to the paddle within the flow switch Replace Flow Switch Remove Blockage YES NO Viewed from ...

Page 53: ...nlet filter for blockage Otherwise incorrect gas supply to boiler Is there at least 18mbar dynamic at gas valve inlet Lead from PCB to Gas Valve faulty Is spark gap between 3 and 4mm Replace spark or flame detection probe and gaskets Is wiring from PCB to spark probe flame detection probe OK NO YES NO NO YES YES NO NO I Remove the larger of the two 6 way PCB connectors Is there continuity from I t...

Page 54: ... combustion chamber door seal trim seal NO YES NO YES Reconnect stat Disconnect fan stat When fan temp 60 C is there continuity across stat Reconnect stat Disconnect the larger of the 6 way PCB connectors Is there continuity across M Disconnect thermistor red sensor on flow pipe Is resistance between 0 5kΩ 20kΩ Is combustion chamber door seal damaged or not in place Replace PCB YES Replace thermis...

Page 55: ...the smaller of the 6 way PCB connector Is there continuity from R to S from T to U from V to W Replace fan Rectify wiring YES N P R V T Q O U Viewed from Wire Entry end S W Fan Connection PCB Connection Fan Connection PCB Connection NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after the boiler has been electrically isolated Lights On on on ...

Page 56: ...ce thermistor Wiring from PCB to thermistor faulty YES NO NO YES Replace PCB Unplug thermistor Is thermistor resistance between 0 5kΩ 20kΩ Plug in thermistor leave 8 way connector unplugged Is resistance at D between 0 5kΩ 20kΩ D Viewed from Wire Entry end Lights On On ...

Page 57: ...blocked or frozen at drain Rectify fault replacing pipe if necessary YES NO Condensate pipe has high resistance too long or restricted head greater than 3 metres Rectify fault replacing or re routing pipe if necessary YES NO Pump motor or impellor worn replace pump assembly Does pump motor stop as level in reservoir falls NO Mechanical fault on float linkage or level switch After 3 mins boiler wil...

Page 58: ... a d r o c c a n i d e l l a t s n i n e e b s a h n i a r d e t a s n e d n o c e h T ALL INSTALLATIONS O C g n i w o l l o f e h t d r o c e r r e r u t c a f u n a m e h t y b d e r i u q e r f I 2 OR CO ppm OR CO CO2 Ratio s e Y s n o i t a l u g e R g n i d l i u B e t a i r p o r p p a e h t h t i w s e i l p m o c m e t s y s r e t a w t o h d n a g n i t a e h e h T s e Y s n o i t c u r t...

Page 59: ...Comments Signature SERVICE 9 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 2 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 4 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 6 Da...

Page 60: ... 0844 871 1560 Technical Enquiries 0844 871 1555 Website www potterton co uk e oe 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 availabl...