Baxi Potterton Gold HE A Range manual

© Baxi Heating UK Ltd 2008 Installation & Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. Gold HE A Range Condensing Combination Boiler You can rely on[...]

2 © Baxi Heating UK Ltd 2008 Natural Gas Potterton Gold Combi 24 HE A G.C.N o 47 393 18 Potterton Gold Combi 28 HE A G.C.N o 47 393 19 Potterton Gold Combi 33 HE A G.C.N o 47 393 20 Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installation of a heating applian[...]

3 Installer Notification Guidelines © Baxi Heating UK Ltd 2008 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 CORGI will record the data[...]

4 Legislation © Baxi Heating UK Ltd 2008 Codes of Practice - refer to the most recent version IMPORTANT - Installation, Commissioning, Service & Repair This appliance must be installed in accordance with the manufacturer’s instructions and the regulations in force. Read the instructions fully before installing or using the appliance. In GB, [...]

5 Safe Manual Handling © Baxi Heating UK Ltd 2008 General The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance. Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shou[...]

6 © Baxi Heating UK Ltd 2008 CONTENTS 1.0 Introduction 7 2.0 General Layout 8 3.0 Appliance Operation 9 4.0 Technical Data 10 5.0 Dimensions and Fixings 11 6.0 System Details 12 7.0 Site Requirements 15 8.0 Flue Options 19 9.0 Plume Displacement 24 10.0 Installation 28 11.0 Commissioning 34 12.0 Completion 37 13.0 Servicing 38 14.0 Changing Compon[...]

7 1.0 Intr oduction © Baxi Heating UK Ltd 2008 1.1 Description 1. The Potterton Gold Combi HE A is a fully automatic gas fired wall mounted condensing combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed domestic hot water. 2. The boiler is set to give a maximum output of :- 24 models - 24 kW DHW 21 [...]

8 2.0 General La yout © Baxi Heating UK Ltd 2008 2.1 Layout 1. Expansion Vessel 2. Automatic Air Vent 3. DHW Plate Heat Exchanger 4. Circulation Pump 5. Drain Off Point 6. Pressure Relief Valve 7. Optional Integral Timer Position 8. Central Heating System Pressure Gauge 9. PCB 10. Control Box 11. 3-Way Valve Assembly 12. Condensate Trap 13. Flame [...]

9 3.0 Appliance Operation © Baxi Heating UK Ltd 2008 3.1 Central Heating Mode (Fig. 2) 1. With a demand for heating, the pump circulates water through the primary circuit. 2. Once main burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor. 3. When the flow temperature exceeds the [...]

10 4.0 T echnical Data © Baxi Heating UK Ltd 2008 4.1 Gold Combi 24, 28 & 33 HE A Flue Terminal Diameter 100mm Dimensions Projection 125mm Outercase Dimensions Casing Height - 780mm Overall Height Inc Flue Elbow - 965mm Casing Width - 450mm Casing Depth - 345mm Central Heating Primary Circuit Pressures bar Safety Discharge 3 Max Operating 2.5 [...]

11 5.0 Dimensions and Fixings © Baxi Heating UK Ltd 2008 Domestic Hot W ater Outlet (15mm) Cold W ater Inlet (15mm) Heating Return (22mm) Heating Flow (22mm) Pressur e Relief V alve (15mm) Gas Inlet (22mm) 65 mm 65 mm 65 mm 65 mm 65 mm 32.5 mm Condensate Drain Tap Rail 360° Orientation Flue Ø 100mm D C B A E G F At least 1.5° H Dimensions A 780[...]

12 6.0 System Details © Baxi Heating UK Ltd 2008 6.1 Information 1. The Potterton Gold Combi HE A Condensing Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN). a) IRN 001 - See text of entry for installation requ[...]

13 6.0 System Details © Baxi Heating UK Ltd 2008 6.5 System Filling and Pressurising (Fig. 4) 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. A filling loop & instructions are provided with the boiler 2[...]

14 6.0 System Details © Baxi Heating UK Ltd 2008 6.8 Domestic Hot Water Circuit (Fig. 7) 1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations. 2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. for IE[...]

15 7.0 Site Requirements © Baxi Heating UK Ltd 2008 7.1 Location 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the build[...]

16 7.0 Site Requirement © Baxi Heating UK Ltd 2008 7.3 Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. 7.4 Gas Supply 1. The gas instal[...]

17 7.0 Site Requirements © Baxi Heating UK Ltd 2008 7.7 Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre) along the entire run. 1. The cond[...]

18 © Baxi Heating UK Ltd 2008 7.0 Site Requirements 7.8 Flue NOTE: Due to the nature 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 recommendations are gi[...]

19 © Baxi Heating UK Ltd 2008 8.0 Flue Options Horizontal Flues Y X Plume Displacement Kit 60 /100 Ø 1M Extensions, 45° & 93° bends are also available - see Section 9.0 Y X This bend is equivalent to 1 metre Total equivalent length = A+B+C+2x90°Bends B A C This bend is equivalent to 1 metre 8.1 Horizontal Flue Systems 1. The standard flue [...]

20 © Baxi Heating UK Ltd 2008 8.0 Flue Options Vertical Flues (Twin Pipe) Y X Vertical Flues Y X The total equivalent length for this example is = 6.5 metres. 1m extension 135°bend 91.5°bend 1m 0.25m 0.5m 5 2 2 5.0m 0.5m 1.0m AIR DUCT N o of fittings/pipes Sub total Equivalent Length Value Equivalent Length Air Duct = 6.5m 1m extension 135°bend[...]

21 © Baxi Heating UK Ltd 2008 8.0 Flue Options B K,K1 R D C N U,W S L H J M E G F P Key Accessory Size Code No FLUE GROUP A Concentric Flue System 100mm diameter A3 Telescopic Internal Flue Kit 315-500mm 5119654 A2 Telescopic Flue (inc. elbow) 315-500mm 5118069 A Horizontal Flue Terminal (inc. elbow) 5118489 B Flue Extension 1000mm 5111074 C Flue [...]

22 © Baxi Heating UK Ltd 2008 8.0 Flue Options For Twin Flue Systems fit the adaptors as follows:- 8.4 Flue Duct Adaptor 1. Engage the flue duct adaptor on the boiler adaptor, making sure that it is pushed down as far as possible. 8.5 Air duct adaptor 1. Undo the screws securing the blanking plate to the boiler top panel. Discard the plate. 2. The[...]

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 aperture in the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained. The adjustable plastic collar can either be positioned on the lead tile or[...]

24 9.0 Plume Displacement © Baxi Heating UK Ltd 2008 9.1 Plume Displacement Kit (Fig. 23) Kit No 5118638 Content of kit 1 0.9m 60/100 Concentric Flue 1 1m 60 Dia Exhaust Flue Pipe 1 Adaptor 2 60 Dia Support Brackets 1 93° Elbow/Plume Outlet Assembly 1 Flexible Flue Trim 3 “O” Rings 1 ‘Jubilee Clip 1 Boiler Elbow 1. This kit is recommended f[...]

25 9.0 Plume Displacement © Baxi Heating UK Ltd 2008 Concentric 60/100 Flue 60Ø Exhaust X Y Fig. 26 2 0 2 4 6 8 10 12 14 60 Ø Exhaust (metres) X Concentric 60/100 Flue (metres) Y 0 16 1 34 6 57 9 8 24 28/33 Fig. 27 2 0 2 4 6 8 10 12 14 60 Ø Exhaust (metres) X Concentric 60/100 Flue (metres) Y 0 16 1 34 6 57 9 8 24 28/33 2 0 2 4 6 8 10 12 14 60 [...]

26 © Baxi Heating UK Ltd 2008 Min. 2 metres Fig. 28 Fig. 33 30mm 30mm Fig. 30 Fig. 32 Fig. 31 Adaptor 9.0 Plume Displacement 50mm Flue Trim Position of ‘Jubilee’ Clip screw Fig. 29 Spigot 9.3 General Fitting Notes 1. Cut a hole in the external wall which the concentric flue assembly will pass through. The hole should allow the flue to fall bac[...]

27 9.0 Plume Displacement © Baxi Heating UK Ltd 2008 9.3 General Fitting Notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air. 16. It is also possible to separate the plume outlet from the 93° elbow to allow the flue to be installed as s[...]

28 © Baxi Heating UK Ltd 2008 10.0 Installation 10.1 Unpacking & Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). NOTE: a small amount of water may drain from the boiler in the upright position. 1. Remove staples, open flaps and remove the cardboard sheet. Remove the[...]

29 10.0 Installation © Baxi Heating UK Ltd 2008 10.3 Fitting the Filling Loop 1. The filling loop supplied with the boiler can be connected to the taps on the wall plate at this point. 2. The filling loop is to be connected between the mains cold water inlet and central heating return isolation taps. 3. The loop and valves must be connected as sho[...]

30 10.0 Installation © Baxi Heating UK Ltd 2008 10.4 Fitting The Boiler 1. Lift the boiler using the Lifting Points as shown by the shaded areas (Fig. 45). The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig. 46) (see Safe Manual Handling page 5). 2. Ease the boiler forwards and remove t[...]

31 10.0 Installation © Baxi Heating UK Ltd 2008 10.7 Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths between 100mm minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (Fig. 48). 2. Locate the flue elbow on the adaptor at the top of the boiler. Se[...]

32 10.0 Installation © Baxi Heating UK Ltd 2008 10.7 Fitting the Flue (Cont) 6. The inner flue duct support bracket may be in the waste portion of the flue. In this case retrieve the bracket before discarding the waste. 7. Take the inner flue support bracket (if not already fitted) and engage it over the flue duct. This will centralise the flue an[...]

33 10.0 Installation © Baxi Heating UK Ltd 2008 Fig. 59 Fig. 58 Cable Clamp Facia Panel Terminal Block Cover 10.8 Making The Electrical Connections The boiler is fitted with a 1.3m length of 3 core cable. This can be connected to the fused 3A 230V 50H Z supply. NOTE: Both the Live and Neutral connections are fused. To connect an external control p[...]

34 11.0 Commissioning © Baxi Heating UK Ltd 2008 11.1 Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Open the mains water supply to the boiler. IMPORTANT: The heat exchanger air vent on top of the boiler (Fig. 62) MUST be opened before filling the primary system. 3. Open all hot water ta[...]

35 11.0 Commissioning © Baxi Heating UK Ltd 2008 11.2 Checking 1. The gas valve is factory set and the burner pressure cannot be measured as it is altered by suction of the fan and modulates as demand on the boiler alters. The gas supply pressure should be 20mb. 2. If necessary the gas rate may be checked after running the boiler for 10 minutes wi[...]

36 11.0 Commissioning © Baxi Heating UK Ltd 2008 11.3 Setting the Timer The Electro-Mechanical Timer allows the central heating system to be set every 15 minutes. Using the three position switch the timer will allow either constant operation, timed operation or central heating off. Move the switch button by sliding to the desired position. Three p[...]

37 12.0 Completion © Baxi Heating UK Ltd 2008 12.1 Completion 1. Instruct the user in the operation of the boiler and system explaining the operational sequence. 2. Set the central heating and hot water temperature control knobs to the requirements of the user. 3. Carefully read and complete all sections of the Benchmark Commissioning Checklist at[...]

38 © Baxi Heating UK Ltd 2008 Case Front Panel Fig. 73 Facia Panel Securing Screws Fig. 74 Inner Door Panel Fig. 75 Sump 13.0 Ser vicing 13 .1 Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person in accordance with B.S. 7967-4:2007. If a sui[...]

39 13.0 Ser vicing © Baxi Heating UK Ltd 2008 13.1 Annual Servicing (Cont) 9. Undo the nut on the gas inlet pipe to the venturi (Fig. 77) and pull the sensing pipe off the fan. 10. Disconnect the electrode leads, noting their position, and the fan electrical plugs. 11. Undo the four nuts retaining the combustion box cover to the heat exchanger. 12[...]

40 14.0 Changing Components © Baxi Heating UK Ltd 2008 IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds [...]

41 14.0 Changing Components © Baxi Heating UK Ltd 2008 Cover Gas Inlet Fan Venturi Injector Collector Burner Gasket When fitting the venturi ensure that the arrow is pointing forward Fig. 82 Fig. 83 Gas Inlet Pipe Venturi Injector Fig. 84 14.3 Fan (Fig. 83) 1. Undo the nut on the gas inlet pipe to the venturi (Fig. 83) and pull the sensing pipe of[...]

42 14.0 Changing Components © Baxi Heating UK Ltd 2008 Fig. 85 Cover Burner Gasket Extension Piece (24 & 28 models) Collector Venturi Heat Exchanger Rear Insulation Cover Insulation Seal Collector Spark Electrode Sensing Electrode Electrode Leads Venturi Fig. 86 14.6 Burner (Fig. 85) 1. Undo the screws securing the collector to the cover and v[...]

43 14.0 Changing Components © Baxi Heating UK Ltd 2008 Central Heating Temperature Sensor Safety Thermostat Flow Pipe Fig. 88 DHW Temperature Sensor Fig. 89 Plate Heat Exchanger Pressure Sensor Flue/Heat Exchanger Thermostat Sensor Electrical Plug Fig. 87 14.8 Flue/Heat Exchanger Thermostat Sensor (Fig. 87) 1. Ease the retaining tab on the sensor [...]

44 14.0 Changing Components © Baxi Heating UK Ltd 2008 14.11 Heat Exchanger Automatic Air Vent (Fig. 90) 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, transferring the grom[...]

45 14.0 Changing Components © Baxi Heating UK Ltd 2008 14.15 Pressure Gauge (Figs. 94 & 95) 1. Drain the boiler primary circuit and undo the nut on the pressure gauge capillary. 2. Undo the screws securing the gauge retaining bracket. 3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining [...]

46 14.0 Changing Components © Baxi Heating UK Ltd 2008 14.18 Plate Heat Exchanger (Fig. 98) 1. Drain the boiler primary circuit and remove the gas valve as described in section 13.22. 2. While supporting the heat exchanger undo the screws securing it to the brass manifolds. 3. Withdraw the heat exchanger upwards, taking care not to damage any wire[...]

47 14.0 Changing Components © Baxi Heating UK Ltd 2008 14.20 P.C.B. (Fig. 102) 1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins. 2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots. Disengage the rear of [...]

48 © Baxi Heating UK Ltd 2008 Gas Valve Valve Inlet Pipe Gas Feed Elbow Fig. 103 Ignition Lead Expansion Vessel Boiler Chassis Lock Nut Fig. 104 Retaining Bracket Sensing Pipe Venturi Inlet Pipe Outlet Adaptor 14.0 Changing Components 14.23 Gas Valve (Fig. 103) IMPORTANT: After replacing the valve the CO 2 must be checked and adjusted as detailed [...]

49 15.0 Combustion Check © Baxi Heating UK Ltd 2008 15.1 Checking the CO 2 IMPORTANT: The CO 2 must only be checked and adjusted if a suitable calibrated combustion analyser is available. 1. The combustion (CO 2 ) may be checked using a suitably calibrated analyser after running the boiler for several minutes. 2. To do this it is necessary to set [...]

50 16.0 Electrical © Baxi Heating UK Ltd 2008 16.1 Illustrated Wiring Diagram - bro wn - black - blue - white br bk b w - green - green / y ellow - red g g/y r Control PCB X2 X3 X9 X501 12 12 3 3 4 4 5 5 678 9 X1 12 DHW NTC Sensor Central Heating NTC Sensor Fan Gas V alve Overheat Stat Flame Sensing Electrode Pump Flue Sensor X400 X401 g g b b r r[...]

51 17.0 Short Par ts List © Baxi Heating UK Ltd 2008 Short Parts List Key G.C. Description Manufacturers No. No. Part No. 326 Fan 5121447 426 Motor 3way Valve 248733 315 Igniter Electrode 5114702 316 Sensing Electrode 5114703 422 Gas Valve 5119647 404 Hall Effect Sensor 5114767 313 Burner 24 5122149 Burner 28 5114697 Burner 33 5114698 419 Water Pr[...]

52 18.0 Fault Finding © Baxi Heating UK Ltd 2008 NOTE: When instructed to turn the selector to the reset position turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler. 18.1 Initial Fault Finding Checks 1. Check that gas, water and electrical supplies are available[...]

53 18.0 Fault Finding © Baxi Heating UK Ltd 2008 Refer to Section 16.0 “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence (do Turn selector switch to The display illuminates Error 20, 28 or 50 flashing Error 119 flashing Burner lights Error 110 flashing Error 130 flashing Error 1[...]

54 18.0 Fault Finding © Baxi Heating UK Ltd 2008 Turn selector switch to The display illuminates Error 20, 28 or 50 flashing Error 119 flashing Burner lights Error 110 flashing Error 133 flashing Turn Domestic Hot Water thermostat to Maximum. Open DHW tap fully. DHW Hall Effect sensor operated (red neon on the sensor illuminated Fan runs Spark at [...]

55 18.0 Fault Finding © Baxi Heating UK Ltd 2008 Fault Finding Solutions Sections Is there 230V at: Is there 230V at: Main terminals L and N Check electrical supply 1. NO Main terminal fuse Replace fuse Replace PCB Display illuminated 2. NO PCB - X1 connector terminals 1,2 Check wiring 3. NO NO A Pump Replace pump 1. YES PCB - X3 connector termina[...]

56 18.0 Fault Finding © Baxi Heating UK Ltd 2008 E20 or E50 - Temperature sensors faulty. Cold resistance approximately 10kΩ @ 25° C (DHW and CH sensors) 20kΩ @ 25° C (Flue sensor) (resistance reduces with increase in temp.) E28 - Incorrect PCB fitted NO E Replace sensor or PCB (E28) Gas at burner Ensure gas is on and purged Replace PCB Replac[...]

57 © Baxi Heating UK Ltd 2008 18.0 Fault Finding Check and correct if necessary 1. The mechanical set of the gas valve (CO2 values - see instruction) 2. Flame sensing electrode and lead connections 3. Flame sensing electrode position Flame current should be more than 0.5 μA Replace PCB Replace PCB YES YES Replace flame sensing electrode NO Check [...]

1 1 1.0 Intr oduction © Baxi Heating UK Ltd 2008 CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER COMBI BOI[...]

59 SERVICE 1 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD S[...]

UK Comp N o 5116282 - Iss 7 - 4/08 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 avai[...]