British Gas Potterton Precision, Installation & Service Instructions Manual

Page 1: ... HomeCare 0800 048 1000 Installation Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Precision Condensing Central Heating Boiler You can rely on ...

Page 2: ...otifying the Local Authority directly The Health Safety Executive operates the Gas Safe Register a self certification scheme for gas heating appliances These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook which was then left on site with the customer With the introduction of S...

Page 3: ...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 Install and Commiss...

Page 4: ...OTE The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty In GB this could also infringe the Gas Safety Installation and Use Regulations Warning Check the information on the data plate is compatible with local supply conditions Codes of Practice most recent...

Page 5: ...r 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 truck ...

Page 6: ...ails 12 7 0 Site Requirements 16 8 0 Flue Options 21 9 0 Plume Displacement 26 10 0 Installation 30 11 0 Electrical 36 12 0 Commissioning the Boiler 38 13 0 Fitting the Outer Case 41 14 0 Servicing the Boiler 42 15 0 Changing Components 45 16 0 Short Parts List 51 17 0 Fault Finding 52 Benchmark Checklist 58 Section Page Contents 6 ...

Page 7: ...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 no 236921 1 2 Important Information Man made mineral fibre Some component parts of this appliance insulation pads gaskets and rope seals are manufactured from man made mineral fibre Prolonged or excessive exposure to this material may result in some irrit...

Page 8: ...ssembly 8 Condensate Trap 9 PCB Housing Assembly 10 Gas Tap 11 Gas Air Ratio Valve 12 Flow Pipe Connection 13 Return Pipe Connection 14 Flow Temperature Safety Thermostat Black 15 Flow Temperature Thermistor Red 16 Flow Switch dry fire protection 17 Output Selector Switch Cover 1 2 3 4 5 6 7 9 8 10 11 15 14 12 13 16 Fig 4 Fig 3 Fig 5 Fig 6 17 ...

Page 9: ...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 pump and fan are on while the spark generator and gas valve are off After 5 seconds if the TRVs are not shut down then pump overrun occurs After 5 seconds if the TRVs are shut down then anti cycle occurs 7 Pump Overrun The pump is...

Page 10: ... Drop mbar 8 17 25 33 42 50 58 66 75 83 91 Pressure Drop in wg Hydraulic Resistance Chart Appliance Type C13 C33 C53 Nox Class 5 Heat Output P Condensing 40 C Mean Water Temp Max Min Setting 1 kW 12 81 10 1 Setting 2 kW 16 49 10 1 Setting 3 kW 19 27 10 1 Setting 4 kW 23 8 10 1 Setting 5 kW 32 61 10 1 Water Content litres 2 6 pints 4 6 Static Head max 30 metres 100 ft min 1 metre 3 25 ft Low Head 0...

Page 11: ...of the flue elbow should be 27 5mm to incorporate the 1 5 fall in the flue from the terminal to the elbow The 1 5 fall provided by the elbow is to allow condensate to run back to the boiler for disposal through the condensate discharge pipe Flue length Y up to 1m 1m 2m 2m 3m Clearance X 27 5mm 55mm 82 5mm 360 Orientation Tube Ø 110mm D C B A E F Y At Least 1 5 X At Least 1 5 Fig 7 Fig 8 ...

Page 12: ...tes within the system risking damage to pump and valves boiler noise and circulation problems When fitting new systems flux will be evident within the system which can lead to damage of system components 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 System addi...

Page 13: ... drop across the 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 An alternative Low Head Installation Fig 12 2 For heads below 400mm then a combined vent and feed pipe may be connected This must be a minimum of 22mm diameter It is ...

Page 14: ...e Cylinder Stat Room Stat Boiler Pump Timer 230V 50Hz L N E L N CH on HW on HW off L N E L N P F E b g y w o gr 1 C 2 g y S Plan Valve Cylinder Stat Room Stat Boiler Pump Timer 230V 50Hz L N E L N CH on HW on L N E L N P F E Motor S Plan Valve Motor o o gr b g y b gr br br Y Plan Diverter Valve Cylinder Stat Boiler Pump Timer 230V 50Hz L N E L N CH on HW on HW off L N E L N P F E b g y o gr 1 C 2 ...

Page 15: ...ted 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 R24 2 of the Water Regulatio...

Page 16: ...evant 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 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 Ins...

Page 17: ...o the appliance is of adequate size to ensure correct operation 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 In IE reference should be made to the current edition of ETCI rules 2 The mains supply is...

Page 18: ...al suitable for external use 9 If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run and sized and insulated accordingly 10 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used and any burrs on cut pipe re...

Page 19: ...lement 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 but below su...

Page 20: ...uisance free dispersal of combustion products Fig 17 Fig 16a 300 min Terminal Assembly TopView Rear Flue Property Boundary Line NOTE The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below Table 2 Terminal Position with Minimum Distance Fig 17 mm Aa Directly below an opening air brick opening windows etc...

Page 21: ...e systems must be securely supported at least once every metre Suitable pipe supports are available as accessories X Y X Y Plume Displacement 70 110 dia Kit 1M Extensions 45 93 bends are also available see Section 9 0 NOTE Horizontal flue pipes should always be installed with a 1 5 fall from the terminal to allow condensate to run back to the boiler Y X This bend is equivalent to 0 5 metre Total e...

Page 22: ...nt length for this example is 17 2 34 4 51 6 metres 1m extension 135 bend 91 5 bend 1m 1 3m 4 8m 5 2 2 5 0m 2 6m 9 6m AIR DUCT No of fittings pipes Sub total Equivalent Length Value Equivalent Length Air Duct 17 2m 1m extension 135 bend 91 5 bend 2m 2 6m 9 6m 5 2 2 10 0m 5 2m 19 2m FLUE DUCT No of fittings pipes Sub total Equivalent Length Value Equivalent Length Flue Duct 34 4m Y X C Roof Termina...

Page 23: ...X T Vertical Flue Boiler Adaptor 5106888 S Flue Terminal Deflector 248167 FLUE GROUP P Twin Flue System 80mm diameter E Flue Extension 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 Pitched Roof Flashing 2...

Page 24: ... 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 ...

Page 25: ... 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 removed prior to commissioning the boiler 8 7 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 270mm 105 8 and 800mm 32 from elbo...

Page 26: ... 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 fitted in the ...

Page 27: ...bly and any extensions and the 70Ø exhaust and any extensions or additional bends Example 1 Not Permissible 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 de...

Page 28: ...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 suitable position fo...

Page 29: ...sed 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 30: ... 20 for wall thicknesses and flue diameters 6 Drill and plug the wall as previously marked Secure the wall plate Fig 22 7 Ensuring the wall plate is level both horizontally and vertically drill and plug at least 5 securing positions at the top and bottom through the wall plate Utilising the slots available ensure the wall plate is square and secure to the wall Fig 22 8 Additionally drill 2 relief ...

Page 31: ... 1 Remove the outer carton and packaging 2 Lift the outercase upwards and remove 3 Remove the internal packaging Fig 22a Internal Polystyrene Packaging Piece Fig 23 Break Off Upper Lower Pipe Run Options B r it is h G a s Lower Door Panel Outercase ...

Page 32: ...is essential that the flow and return pipes are connected to the boiler correctly The flow connection incorporates the boiler thermostats and a flow switch 3 The boiler connections will accept 22mm fittings NOTE When the output is at setting 5 see Section 12 1 28mm pipe should be used to connect to the boiler flow and return using suitable reducing fittings 4 If the installation requires that the ...

Page 33: ...3 Take the flue and mark off X from the terminal end as indicated in the diagram Fig 27 Check your dimensions The flue tubes are fixed together Cut through both tubes whilst resting the flue on the semi circular packing pieces Deburr both tube ends 4 For side exit measure the distance from the edge of the wall plate to the inner face of the wall Fig 26 and to this dimension add the wall thickness ...

Page 34: ...oiler Secure with the four screws supplied in the kit 11 Make good between the wall and air duct outside the building ensuring the 1 5 drop between the terminal and elbow 12 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 is dust free and dry 13 ...

Page 35: ... prevent damage to the cable 4 Lay the cable through the cable clamp to gauge the length of cable required when it is connected to the 4 way terminal block 5 Connect the S L N and wires to the 4 way terminal block Fig 33 and refit the cable clamp Fig 31 6 Check the electrical installation for earth continuity short circuits resistance to earth correct polarity and fuse failure Fig 33 S L N Fig 31 ...

Page 36: ...op Opaque y Yellow Gas Valve g op Spark Electrode g y bk bk bk bk r w w Flame Detection Electrode Condensate Trap Flow Overheat Thermostat Fan Overheat Thermostat g y r b r r Flow Thermistor 325Vdc DC Fan CH Flow Switch gy w g br PCB Earths not shown to aid clarity of diagram g y b y L N Optional Pump Feed br g y br b op op Output Selector b pu b pu gy ...

Page 37: ...1 2 Illustrated Wiring Diagram GasValve Fan CondensateTrap CH Flow Switch Flow Thermistor Spark Electrode Flame Detection Electrode Main PCB N L r r gy gy r b br g w Flow Overheat Thermostat Fan Overheat Thermostat bk bk bk r bk w w op g y Layout of PCB Pins Optional Pump Feed g y br y g y b br b y b br br b b pu pu Output Selector ...

Page 38: ...nel Fig 34a This must be performed by a competent registered person The ELECTRICAL SUPPLY to the boiler MUST BE ISOLATED BEFORE ADJUSTMENT Take the IMPORTANT label from the fitting kit and apply firmly over the Output Selector Switch Cover securing screw If the highest output is selected 28mm pipe should be connected to the boiler flow and return pipes No adjustment of the gas valve is permissible...

Page 39: ...accordance with the GSIUR Note Check record the CO combustion ratio at both maximum a low rate before calling 0844 871 1555 Yes No No Yes Yes No Is CO 350ppm and CO CO2 ratio 0 004 No Yes BOILER OPERATING SATISFACTORILY NO FURTHER ACTION REQUIRED Ensure test points are capped the boiler case front panel is correctly fitted secured and all other commissioning procedures completed Complete the Bench...

Page 40: ...y working Measure the Gas Rate 4 With any other appliances pilot 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 pu...

Page 41: ...ations This is in addition to the Benchmark Commissioning Checklist 5 Instruct the user in the operation of the boiler controls Hand over the User s Operating Installation and Servicing Instructions giving advice on the necessity of regular servicing 6 Demonstrate to the user the action required if a gas leak occurs or is suspected Show them how to turn off the gas supply at the meter control and ...

Page 42: ...ation Maintenance of Gas Fired Boilers not exceeding 70kW advises that The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements ...

Page 43: ...e Section 13 0 WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate at supply before access 7 Release the four 1 4 turn screws securing the air box door panel and remove the door Fig 39 8 Disconnect the leads from the centre and right hand terminals earth and flame sensing probe Fig 40 Reconnect in reverse order 9 Undo the four screws securing the combustion box door and remove the door Fi...

Page 44: ... and withdraw the base j Lower the central insulation panel and check condition Fig 44 Replace the lower insulation pad if necessary k Ensure the heat exchanger fins are clear of any obstruction l Check condition of all seals Important Pay particular attention to the condition of the combustion box door seals m Reassemble in reverse order and check for leaks 12 Check the CO CO2 ratio and CO2 level...

Page 45: ...ss 3 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 4 Place a tube on the drain point to drain water away from electrics Turn anticlockwise to open Fig 45 NOTE When reassembling always fit new O rings ensuring their correct location on the spig...

Page 46: ... 15 4 PCB Figs 48 49 WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate at supply before access 1 Remove the plastic button cover Refit them onto the new PCB Fig 48 1 Remove the top right hand securing screw and hinge down the PCB housing and disconnect the electrical connections noting their positions NOTE Check the PCB for the presence of input jumpers see section 10 8 Set the new PCB ...

Page 47: ...PCB Control and Fan Assembly are 325 Vdc Isolate at supply 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 fan protection sens...

Page 48: ... to the new valve 10 Fit the new gas valve and reassemble in reverse order NOTE Check for gas tightness after replacing gas valve 11 Check the CO CO2 ratio and CO2 level at the flue sampling point Fig 41a is as quoted in Section 4 0 Technical Data 12 If the ratio or level is greater than that quoted telephone the Technical Enquiries for further advice IMPORTANT No adjustment of the gas valve is pe...

Page 49: ...urner and reassemble in reverse order 15 11 Heat Exchanger 1 Drain the boiler see section 15 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 Lift the h...

Page 50: ... pad and reassemble in reverse order 15 14 Output Rotary Selector Switch Fig 61 1 Ensure that the electrical supply to the boiler is isolated and undo the screw securing the Output Selector Switch Cover 2 Note the position of the control knob Pull the knob off the Selector Switch Ease the bracket to the right and forwards disengaging the keyhole slot from the locating screw 3 Slacken the locknut h...

Page 51: ...erature Thermistor Red 240670 B E06 059 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 5132097 J Burner Assy 5107430 K E06 097 Heat Exchanger Assy 242497 A B C E F G H I J K D ...

Page 52: ...ace selector switch or wiring 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 ON 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 s...

Page 53: ...ols and System Wiring 240V at B Check wiring from terminal block to PCB Check for shorts on pump fan gas valve Replace if shorted replace fuse YES NO Replace PCB YES YES NO NO ELECTRICAL SUPPLY 240V at A PCB fuse OK B Fuse A N L Lights Off Off Off ON Optional Pump Live ...

Page 54: ... 5 sec is there 240V at E Pump or Pump Wiring fault Is there a blockage in the system NO YES YES E Optional Pump Live N L F N L Turn mains off unplug 7 way connector to PCB Is there continuity between F and G Wiring from terminal block to PCB faulty NO 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...

Page 55: ...ry YES YES NO NO YES Remove Gas Valve check inlet 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 or the two 6 wa...

Page 56: ...er 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 thermistor M 6 way Conne...

Page 57: ...d 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 Flash Flash On ON THERMISTOR Replace 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 leav...

Page 58: ...uired 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 tempe...

Page 59: ...ompany 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 max ...

Page 60: ... 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 Manufactured by Potterton exclusively for British Gas A Trading Division of Baxi Heating UK Ltd 3879156 Brooks House Coventry Road Warwick CV34 4LL e oe 7209192 06 1 14 ...