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Baxi Potterton Gold FSB 30 HE manual

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Table of contents for the manual

  • Page 1

    © Baxi Heating UK Ltd 2011 Installation & Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. Gold FSB 30 HE Floor Standing Condensing Boiler You can rely on[...]

  • Page 2

    2 © Baxi Heating UK Ltd 2011 Natural Gas Potterton Gold FSB 30 HE G.C. No. 41 592 32 © Baxi Heating UK Ltd 2011 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, rec[...]

  • Page 3

    Installer Notification Guidelines 3 © Baxi Heating UK Ltd 2011 Choose Building Regulations Notification Route Contact your rele v ant Local A uthor ity Building Control (LABC) who will arrange an inspection or contact a gov er nment approv ed inspector LABC will record the data and will issue a cer tificate of compliance ‘Gas Safe Register’ wi[...]

  • Page 4

    Legislation 4 © Baxi Heating UK Ltd 2011 This company declare that no substances harmful to health are contained in the appliance or used during appliance manufacture. The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force, and only used in a suitably ventilated location. In GB, t[...]

  • Page 5

    5 © Baxi Heating UK Ltd 2011 1.0 Introduction 6 2.0 General Layout 7 3.0 Boiler Operation 8 4.0 Technical Data 9 5.0 Dimensions and Fixings 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 Bo[...]

  • Page 6

    1.1 Description 1. The Potterton Gold FSB 30 HE is a gas fired room sealed fan assisted condensing central heating boiler. 2. The maximum output of the boiler is 30.18 kW (Non - Condensing) 32.61 kW (Condensing). 3. The boiler is designed for use on Natural Gas (G20) only. 4. The boiler is suitable for fully pumped open vented and sealed systems, p[...]

  • Page 7

    2.0 General La yout 7 © Baxi Heating UK Ltd 2011 2.1 Layout (Figs. 3, 4, 5 & 6) 1. Condensate Pump 2. Flue Elbow (supplied in std. flue kit) 3. Heat Exchanger 4. Burner 5. Air Box 6. Fan Protection Thermostat - Black 7. Fan Assembly 8. Condensate Trap 9. PCB Housing Assembly 10. Gas Tap 11. Gas / Air Ratio Valve 12. Flow Pipe Connection 13. Re[...]

  • Page 8

    3.1 Boiler Operation 1. Switched Live On: When switched live is supplied to the boiler and the flow temperature is less than the set point the sequence below commences. 2. Flow Switch: After 10 seconds if the flow switch has made then fan pre-purge occurs. After 10 seconds if the flow switch has not made then anti-cycle occurs. 3. Fan Pre-Purge: Th[...]

  • Page 9

    Appliance Category CAT I 2H 4.0 T echnical Data 9 © Baxi Heating UK Ltd 2011 Horizontal Flue Terminal Diameter - 110mm Dimensions Projection - 150mm Outercase Dimensions Casing Height - 850mm Casing Width - 390mm Casing Depth - 520mm Weights kg Packaged Boiler Carton - 49.5 Packaged Flue Kit - 3.6 Installation Lift Weight - 37.5 Installed Weight ([...]

  • Page 10

    5.0 Dimensions and Fixings 10 © Baxi Heating UK Ltd 2011 DIMENSIONS A 850mm B 520mm C 390mm D 125mm Ø Min. E 175mm F 150mm SIDE FLUE (left and right) For every 1m of horizontal flue length, the clearance above the top of the flue elbow should be 27.5mm to incorporate the 1.5° fall in the flue from the terminal to the elbow. It is especially impo[...]

  • Page 11

    6.0 System Details 11 © Baxi Heating UK Ltd 2011 6.1 Water Circulating Systems 1. The boiler is suitable for use with open vent fully pumped systems and sealed systems . The following conditions should be observed on all systems: • The static head must not exceed 30m of water. • The boiler must not be used with a direct cylinder. • Drain coc[...]

  • Page 12

    6.0 System Details 12 © Baxi Heating UK Ltd 2011 6.3 Pipework 1. The sizes of flow and return pipes from the boiler should be determined by normal methods, according to the requirements of the system. 2. The connection tails for the boiler are 28mm diameter. The 28mm section of the tails can be cut back to 22mm if required. 3. The flow & retur[...]

  • Page 13

    6.0 System Details 13 © Baxi Heating UK Ltd 2011 6.6 System Controls & Wiring This boiler requires a permanent live for operation of the condensate pump and frost protection. 1. To comply with Part L1 of the Building Regulations the heating system into which the boiler is installed should include the following: a) zone controls b) timing contr[...]

  • Page 14

    6.0 System Details 14 © Baxi Heating UK Ltd 2011 6.7 Sealed Systems (Fig. 13) 1. SAFETY VALVE - A safety valve complying with the requirements of BS 6750 Part 1 must be fitted close to the boiler on the flow pipe by means of a horizontal or vertically upward connection with no intervening valve or restrictions and should be positioned to facilitat[...]

  • Page 15

    7.0 Site Requirements 15 © Baxi Heating UK Ltd 2011 7.1 Location NOTE: Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. 1. The boiler must be fitted on a suitable flat and level surface capable of supporting the weight. Any wall behin[...]

  • Page 16

    7.0 Site Requirements 16 © Baxi Heating UK Ltd 2011 7.3 Clearances (Figs. 15 &16) 1. These dimensions include the necessary clearances around the boiler for case removal, spanner access and air movement. Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of[...]

  • Page 17

    7.0 Site Requirements 17 © Baxi Heating UK Ltd 2011 7.6 Condensate Drain - General Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler. 1. Ensure the discharge of condensate complies with any national or local regulations in force. BS 6798 & Part H1 of the Building Regulations give fu[...]

  • Page 18

    7.0 Site Requirement 18 © Baxi Heating UK Ltd 2011 7.7 Condensate Disposal (cont.) 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. C. ii) to an internal or [...]

  • Page 19

    7.0 Site Requirements 19 © Baxi Heating UK Ltd 2011 7.8 Flue NOTE: Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. 1. The following guidelines indicate the general requirements for siting balanced flue terminals. For GB recommendatio[...]

  • Page 20

    8.0 Flue Options 20 © Baxi Heating UK Ltd 2011 (i) 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. (ii) (i) This bend is equivalent to 0.5 metre Total [...]

  • Page 21

    8.0 Flue Options 21 © Baxi Heating UK Ltd 2011 (ii) (ii) (i) (ii) (i) C Roof Terminal A B This bend is equivalent to 1 metre Total Equivalent Length = A+B+C+1x90°Bend All vertical and angled runs must be included, measured from the boiler adaptor (point X) to the joint with the flue terminal (point Y). One 91.5° bend or two 135° bends can be in[...]

  • Page 22

    8.0 Flue Options 22 © Baxi Heating UK Ltd 2011 Key Accessory Size Code No FLUE GROUP B Concentric Flue System 110mm diameter A1 Horizontal Flue Terminal 850mm 243013BAX A Horizontal Flue Terminal (incl elbow) 236921 B Flue Extension 1000mm 241695 500mm 241694 250mm 241692 C Flue Bend 93° 241687 D Flue Bend (pair) 135° 241689 U Pipe Support 110mm[...]

  • Page 23

    8.0 Flue Options 23 © Baxi Heating UK Ltd 2011 Vertical Flue Adaptor Gasket 8.4 For Vertical Flue Systems 1. Undo the screws securing the blanking plate to the boiler top panel. Discard the plate. 2. 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 bl[...]

  • Page 24

    8.0 Flue Options 24 © Baxi Heating UK Ltd 2011 Fig. 18 Fig. 18a Fig. 19 270mm 800mm Push Fit Adaptor Air Duct Flue Duct Cut the same amount off the Air Duct & Flue Duct Approx 1425mm Flue Deflector 8.6 For Roof Terminals 1. In the case of a pitched roof 25 - 50 degrees, position the lead tile to replace/flash over existing roof tiling. Make an[...]

  • Page 25

    9.0 Plume Displacement 25 © Baxi Heating UK Ltd 2011 9.1 Plume Displacement Kit (P.D.K.) Kit No 5121371 Content of kit 1 70/110 Concentric Flue 1 1m 70 Dia Exhaust Flue Pipe 2 Support Brackets 1 93° Elbow/Plume Outlet Assembly 1 Flue Trim 2 “O” Rings 1 Elbow with Gasket 1. This kit is recommended for installations where the condensate plume e[...]

  • Page 26

    9.0 Plume Displacement 26 © Baxi Heating UK Ltd 2011 1 0 2 4 6 8 10 12 14 70Ø Exhaust (metres) Concentric 70/110 Flue (metres) 0 16 18 23 4 20 30 22 24 26 28 30 1 0 2 4 6 8 10 12 14 70Ø Exhaust (metres) Concentric 70/110 Flue (metres) 0 16 18 23 4 20 30 22 24 26 28 30 1 0 2 4 6 8 10 12 14 70Ø Exhaust (metres) Concentric 70/110 Flue (metres) 0 1[...]

  • Page 27

    9.0 Plume Displacement 27 © Baxi Heating UK Ltd 2011 9.3 General Fitting Notes - P.D.K. 1. Cut a hole in the external wall which the horizontal concentric flue assembly will pass through. 2. When completed the terminal must be at least 2 metres above ground level (Fig. E). 3. Measure and cut to size the concentric assembly and any extensions that [...]

  • Page 28

    9.0 Plume Displacement 28 © Baxi Heating UK Ltd 2011 500mm Min. Plume Outlet Elbow 200mm Min. 9.3 General Fitting Notes - P.D.K. (cont.) 16. For aesthetic purposes it is permissible to route the 70Ø exhaust 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[...]

  • Page 29

    10.0 Installation 29 © Baxi Heating UK Ltd 2011 Check Site Requirements before commencing. 10.1 Initial Preparation & Installation 1. Remove the outer carton. 2. For the boiler to operate correctly it must be level in both planes. Place the fixing template in the proposed boiler position ensuring that it is level. 3. Mark the centre of the flu[...]

  • Page 30

    10.0 Installation 30 © Baxi Heating UK Ltd 2011 10.5 Fitting the Standard Flue IMPORTANT: The flue should always be installed with at least 1.5° fall from terminal to elbow, to allow condensate to run back to the boiler. 1. The standard flue is suitable for lengths 270mm minimum to 800mm maximum (measured from the edge of the flue elbow outlet). [...]

  • Page 31

    10.0 Installation 31 © Baxi Heating UK Ltd 2011 10.5 Fitting the Standard Flue (Cont) 7. Ensure the inner flue support bracket is positioned in the flue (Fig. 28). 8. Engage the flue into the flue elbow using soap solution to ease the engagement, ensuring the flue terminal is positioned as shown (Fig. 29). 9. Place the gasket over the flue exit on[...]

  • Page 32

    32 © Baxi Heating UK Ltd 2011 10.0 Installation 10.6 Making the Condensate Drain Connection 1. 3.5 metres of flexible 10mm PVC pipe are supplied with the boiler, ready connected to the pump. 0.5 metres of this length remains coiled within the boiler to allow removal of the pump assembly. This must not be uncoiled to provide extra length. 2. A fitt[...]

  • Page 33

    10.0 Installation 33 © Baxi Heating UK Ltd 2011 10.7 Making The Electrical Connections WARNING: This boiler must be earthed IMPORTANT: Four core cable is required to supply the boiler as a permanent live is necessary for the operation of the condensate pump and frost protection. 1. The electrical connections are on the right hand side of the boile[...]

  • Page 34

    11.0 Electrical 34 © Baxi Heating UK Ltd 2011 11.1 Schematic Wiring Diagram Key To Wiring Colours b- B l u e bk - Black w- W h i t e br - Brown gy - Grey o - Orange r- R e d g - Green g/y- Green/Yellow op - Opaque y - Yellow v - Violet Gas V alve g/y op Spark Electrode bk bk bk bk r w w Flame Detection Electrode Condensate Tr a p Flow Overheat The[...]

  • Page 35

    11.0 Electrical 35 © Baxi Heating UK Ltd 2011 Wiring Key b- B l u e bk - Black br - Brown r- R e d w- W h i t e g/y - Green/Yellow g - Green gy - Grey op - Opaque y - Yellow 11.2 Illustrated Wiring Diagram Gas V alve Fan Condensate T r ap CH Flow Switch Flow Thermistor Spar k Electrode Flame Detection Electrode Main PCB N P/L S/L r r gy gy b br g [...]

  • Page 36

    12.0 Commissioning the Boiler 36 © Baxi Heating UK Ltd 2011 IN OUT Gas Service Cock Fig. 34 Fig. 35 Fig. 36 Open Inlet Gas Pressure Test Point DO NOT check gas pressure here Low High Reset Central Heating Control Knob (No OFF Position) T urn the Central Heating Control Knob clockwise to increase or anticlockwise to decrease the boiler flow tempera[...]

  • Page 37

    12.0 Commissioning the Boiler 37 © Baxi Heating UK Ltd 2011 12.3 Check the Operational (Working) Gas Inlet Pressure 1. Ensure that all controls are calling for heat and maximum load is applied to the system. 2. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test p[...]

  • Page 38

    13.0 Completion 38 © Baxi Heating UK Ltd 2011 13.1 Fitting The Case Panels & Facia 1. Refit the case top panel and front door, securing with the screws previously removed (Fig.37). 2. Locate the facia panel and secure with the screws previously removed (Fig. 38). 3. The “Important Ventilation Information” label can be removed unless the bo[...]

  • Page 39

    14.0 Ser vicing the Boiler 39 © Baxi Heating UK Ltd 2011 14.1 Annual Servicing WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate system controls before access. IMPORTANT: When servicing ensure that both the gas and electrical supplies, including Switched and Permanent Live to the boiler are isolated before any work is started. The fou[...]

  • Page 40

    14.0 Ser vicing the Boiler 40 © Baxi Heating UK Ltd 2011 14.2 Annual Servicing - Inspection WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate system controls before access 1. Ensure that the boiler is cool. 2. Remove the facia and front door panel. 3. Release the four 1 / 4 turn screws securing the air box door panel and remove the pa[...]

  • Page 41

    14.0 Ser vicing the Boiler 41 © Baxi Heating UK Ltd 2011 14.2 Annual Servicing - Inspection (Cont) 7. To clean the heat exchanger and burner proceed as follows: a) Disconnect the electrical leads to the fan component protection sensor (Fig. 42). b) Loosen the screw retaining the gas injector pipe at the venturi (Fig. 42). c) Undo the two wing nuts[...]

  • Page 42

    15.0 Changing Components 42 © Baxi Heating UK Ltd 2011 15.1 Changing Components & Preparation WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate system controls before access. IMPORTANT: Ensure that both the gas and electrical supplies, including Switched and Permanent Live to the boiler are isolated before any work is started. The[...]

  • Page 43

    15.0 Changing Components 43 © Baxi Heating UK Ltd 2011 15.3 Flowswitch (Fig. 47) 1. Drain the boiler (see Section 13.1 paragraph 2 & 3). 2. Remove the pipe access panel and remove the securing clip from the ‘O’ ring joint between the flow pipe and the system. Undo screws on support bracket. 3. Remove the securing clip from the ‘O’ ring[...]

  • Page 44

    15.0 Changing Components 44 © Baxi Heating UK Ltd 2011 15.6 PCB (Figs. 48 & 49) WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate system controls before access. 1. Pull the control knob off the spindle and remove the plastic button cover. Refit them onto the new PCB (Fig. 48). 2. Remove the top right hand securing screw and swing [...]

  • Page 45

    15.0 Changing Components 45 © Baxi Heating UK Ltd 2011 The fan and venturi, gas valve, injector pipe, condensate trap, fan protection sensor, spark and sensing electrodes can be accessed and changed on the removal of the airbox door panel. 1. Remove the airbox door panel by loosening the four 1 / 4 turn screws (Fig. 50). 15.7 Spark and Sensing Ele[...]

  • Page 46

    15.0 Changing Components 46 © Baxi Heating UK Ltd 2011 The removal of the fan is necessary to enable the changing of the injector pipe, condensate trap and gas valve (see section 13.6). 15.9 Injector Pipe (Fig. 53) 1. Remove the injector pipe by pulling out from the ‘O’ ring joint in the gas valve. 2. Fit the new injector pipe and reassemble i[...]

  • Page 47

    15.0 Changing Components 47 © Baxi Heating UK Ltd 2011 The burner and heat exchanger can be changed after removal of the combustion box door. To change the heat exchanger, the fan and burner must be removed first (see section 13.6 and 13.10). 1. Remove the combustion box door by removing the four securing screws (Fig. 55). IMPORTANT: On refitting [...]

  • Page 48

    15.0 Changing Components 48 © Baxi Heating UK Ltd 2011 Combustion Box Base Central Insulation Panel Support Bracket Burner 15.14 Heat Exchanger Lower 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 four bolts securing the combustion box base. 4. Remove the combust[...]

  • Page 49

    16.0 Short Par ts List 49 © Baxi Heating UK Ltd 2011 Short Parts List Key G.C. Description Manufacturers No. No. Part No. A E06 058 Flow Temperature Thermistor (Red) 240670 B E 06 059 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 511171[...]

  • Page 50

    17.0 Fault Finding 50 © Baxi Heating UK Ltd 2011 Mains On LED Light (Green) Boiler On LED Light (Green) Lockout LED Light (Red) Live & Neutral Reversed Incoming Live and Neutral reversed. Go to Ignition Lockout section of the fault finding instructions. Go to Fan Lockout section of the fault finding instructions. Go to Thermistor section of th[...]

  • Page 51

    17.0 Fault Finding 51 © Baxi Heating UK Ltd 2011 No Switched Live to boiler. Check System Controls and System Wiring. 240V at C ? Check P/L wiring from terminal 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 fu[...]

  • Page 52

    17.0 Fault Finding 52 © Baxi Heating UK Ltd 2011 DRY-FIRE NO Fill system with water and bleed out all air. YES NO YES NO Is the system full of water ? Is the pump running ? Unplug 5-way PCB connector. Is there continuity between H Disconnect Flow Switch Inline connector. With pump running is there continuity across flow switch ? Remove Blockage. N[...]

  • Page 53

    17.0 Fault Finding 53 © Baxi Heating UK Ltd 2011 IGNITION LOCKOUT YES Is there gas at gas valve inlet ? Check isolation valve and gas supply. YES NO Reset Lockout. Is there gas flow (check at meter) ? Remove 5-way connector from gas valve. Is there 240 Vdc between I & J during ignition ? Is spark or flame detection probe damaged ? Replace PCB.[...]

  • Page 54

    17.0 Fault Finding 54 © Baxi Heating UK Ltd 2011 OVERHEAT LOCKOUT Replace Stat. Replace Stat. Wiring from PCB to thermostats faulty. YES NO YES NO NO Disconnect black stat on flow pipe. When flow < 60° C is there continuity across stat ? Replace combustion chamber door seal & trim seal. NO YES NO YES Reconnect stat. Disconnect fan stat. Wh[...]

  • Page 55

    17.0 Fault Finding 55 © Baxi Heating UK Ltd 2011 FAN LOCKOUT Rectify wiring. NO YES Unplug 3-way PCB connector & unplug fan. Is there continuity from N to O & from P to Q ? NO Unplug 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[...]

  • Page 56

    17.0 Fault Finding 56 © Baxi Heating UK Ltd 2011 THERMISTOR Replace thermistor. Wiring from PCB to thermistor faulty. YES NO NO YES Replace PCB. Unplug thermistor, Is thermistor resistance between 0.5k ë & 20k ë ? Plug in thermistor, leave 8-way connector unplugged. Is resistance at D between 0.5k ë & 20k ë ? D Viewed from Wire Entry e[...]

  • Page 57

    57 © Baxi Heating UK Ltd 2011 17.0 Fault Finding CONDENSATE PUMP Lights On * * NO NO Reset boiler and add approx. 1 litre tap water to the condensate system via the flue or sample point YES Mechanical fault on float, linkage or switch. Mechanical fault on pump or impellor. Does the pump motor run as the condensate level rises ? As the pump motor r[...]

  • Page 58

    Failure to install and commission accor ding to the manufacturer’ s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty . This does not affect the customer’ s statutory rights. If yes, and if required by the manufactur er , has a water scale reducer been fitted? CONDENSING BOILERS ONL Y The condensate [...]

  • Page 59

    Service Record It is recommended that your heating system is serviced r egularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appr opriate Service Record below , please ensure you have carried out the service as described in the manufacturer’ s instructions. Always use the manufacturer’ s[...]

  • Page 60

    © Baxi Heating UK Ltd 2011 Comp No. 720896601 (6/11) 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 All descriptions and illustrations provided in this leaflet have been carefully pr[...]