Baxi Potterton Gold Combi 24 HE Installation & Service Instructions Manual Download Page 19 | Manualshive

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Summary of Contents for Gold Combi 24 HE

Page 1: ...3 and is deemed to meet the requirements of Directive 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purpose of Regulation 5 certified by Notified Body 0051 Product Production certified by Notified Body 0051 For use in GB IE only These instructions include the Benchmark Commissioning Checklist and should be left with the U...

Page 2: ...uctions Baxi PoUerton is a member of the Benchmark initiative and fully supports the aims of the programme Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency Building Regulations require that installations should comply with manufacturer s in...

Page 3: ... on member s behalf Contact your relevant Local Authority Building Control LABC who will arrange an inspection or contact a government approved inspector Scheme Members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days You must ensure that the notification number issued by CORGI is writen onto the Benchmark Checklist CORGI will record the data and will send a certif...

Page 4: ... be installed in accordance with the rules in force and only used in a suitably ventilated location In GB the installation must be carried out by a CORGI Registered Installer It must be carried out in accordance with the relevant requirements of the Gas Safety Installation Use Regulations The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Buildin...

Page 5: ...gives details of the model serial number and Gas Council number and is situated on the control box It is visible when the case front panel is removed Fig 1 6 The boiler is intended to be installed in residential commercial light industrial E M C environments on a governed meter supply only 7 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue ki...

Page 6: ...nstalled in accordance with the rules in force and only used in a suitably ventilated location In GB the installation must be carried out by a CORGI Registered Installer It must be carried out in accordance with the relevant requirements of the Gas Safety Installation Use Regulations The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Reg...

Page 7: ...re Relief Valve 9 Optional Integral Timer Position 10 Central Heating System Pressure Gauge 11 Control PCB 12 Control Box 13 3 Way Valve Assembly 14 Condensate Trap 15 Flame Sensing Electrode 16 Spark Electrode j 4 17 Burner 18 Primary Heat Exchanger 19 Fan Assembly 20 Secondary Heat Exchanger 21 On Off Reset Selector Switch 22 Burner Fault Indicator Neon 23 Power Neon 24 Flame Failure Fault Indic...

Page 8: ...of the domestic hot water is controlled by the temperature sensor 4 When the domestic hot water demand ceases the burner will extinguish and the diverter valve will remain in the domestic hot water mode unless there is a demand for central heating IMPORTANT When the selector switch is in the 0 Off position the electrical supply to the boiler is isolated The boiler will not operate and the integral...

Page 9: ...ce of 5mm at the right This is also sufficient for routine maintenance However a clearance of 20mm is required if it is necessary to remove the secondary heat exchanger This should be considered when siting the appliance and in the event of any subsequent alterations in the area of installation Weights Packaged Boiler Carton Installation Lift Weight kg 50 43 5 5 4 5 4 3 5 3 E 2 5 2 1 5 0 5 0 0 200...

Page 10: ...ions A A 780mm B 345mm C 450mm D 116mm0 Min E 185mm T c 1 F 190mm G 131mm Tube 0 100mm Gas Inlet Condensate Drain u0 68mm 11 j Heating Return Domestic Hot Cold Water Water Outlet Inlet U u ui u 0 un u0r 65mm 65mm 65mm 95mm u0 u u 65mm Left Hand Side of Boiler 265mm 165 7mm View from under the appliance 130mm Fig 7 9 ...

Page 11: ...em which can lead to damage of system components All systems must be thoroughly drained and flushed out The recommended flushing and cleansing agents are Betz Dearborn Sentinel X300 or X400 and Fernox Superfloc Universal Cleanser which should be used following the flushing agent manufacturer s instructions System additives corrosion inhibitors and flushing agents descalers should be suitable for a...

Page 12: ...after use 6 6 Expansion Vessel Central Heating only 1 The appliance expansion vessel is pre charged to 0 5 bar Therefore the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt 1 For IE the current edition of I S 813 Domestic G...

Page 13: ... If the hot water expansion is not provided for then high pressures can develop which may result in damage to fittings and devices on the system 6 The boiler s maximum working mains pressure is 8 bar therefore all pipework connections fittings etc should be suitable for pressures in excess of 8 bar A pressure reducing valve must be fitted for pressures in excess of 8 bar The manufacturer of any ou...

Page 14: ... current ETCI rules 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing 7 2 Clearances Fig 11 12 1 A flat vertical area is required for the installation of the boiler 2 These dimensions include the necessary clearances around the ...

Page 15: ...cock Fig 13 3 Ensure that the pipework from the meter to the appliance is of adequate size Do not use pipes of a smaller diameter than the boiler gas connection 22mm 7 5 Electrical Supply Fig 13 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 edit...

Page 16: ...e pipe diameter is increased to 32mm 8 Ifthe boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run 9 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 10 When discharging condensate into a soil stack or waste ...

Page 17: ...on the terminal should be no nearer than 150mm to an opening in the building fabric formed for the purpose of accommodating a built in element such as a window frame See BS 5440 Pt 1 7 0 SITE REQUIREMENTS 7 7 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 i...

Page 18: ...de wall or on the inner wall of installation 7 10 Terminal Guard Fig 17 1 When codes of practice dictate the use of terminal guards they can be obtained from most Plumbers and Builders Merchants 2 There must be a clearance of at least 50mm between any part of the terminal and the guard 3 When ordering a terminal guard quote the appliance name and model number 4 The flue terminal guard should be po...

Page 19: ...stem must be taken into consideration Their equivalent lengths are Concentric Pipes 45 bend 93 bend Twin Flue Pipe 45 bend 91 5 bend 0 5 metres 1 0 metres 0 25 metres 0 50 metres The elbow supplied with the standard horizontal flue is not included in any equivalent length calculations 5 The illustrations opposite show examples of maximum equivalent lengths 6 Instructions for guidance and fitting a...

Page 20: ...as shown 4 If required mark the position of the gas and water pipes Remove the template 5 Cut the hole for the flue minimum diameter 116mm 6 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using two of the fixing screws 7 Using a spirit level ensure that the plate is level before finally tightening the screws 8 2 Flushing 1 Connect a tube to the central ...

Page 21: ...e cock and hot water outlet pipe and then connect the elbows to the boiler Connect the elbows with flared ends to the valves 7 Ensure that the sealing washers are used on all connections The rubber washers must be used on the gas connections 8 The gas and water supplies central heating flow and return and domestic hot water flow can now be connected 8 5 Fitting the Pressure Relief Discharge Pipe F...

Page 22: ...tside drain is acceptable J 8 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 23 2 Locate the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 24 NOTE The flue elbow is angled at ...

Page 23: ...t if not already fitted and engage it over the flue duct This will centralise the flue and air ducts and ease assembly Fig 27 8 Insert the flue through the hole in the wall Fit the elbow to the boiler adaptor ensuring that it is pushed fully in 9 Draw the flue back through the wall and engage it in the elbow It may be necessary to use soap solution or similar to ease assembly of the elbow adaptor ...

Page 24: ...ching 8 Ensure that both mains input and where fitted external control input cables have sufficient slack to allow the control box to drop down Tighten the cable clamp s on the boiler chassis 9 If an optional integral timer is to be used it should be fitted at this point Refer to the instructions supplied with the timer NOTE An external frost thermostat cannot be used with the integral timer I 8 9...

Page 25: ...he system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 7 Pressurise the system to at least 0 5 bar then close and disconnect the filling loop Fig 34 8 Turn the gas supply on and purge the system according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 9 Test for gas soundness 0 10 If at any time during commissioning it ...

Page 26: ...21 8 mbar Ifnot check that the gas supply pressure is correct Natural Gas 20mbar and Propane 37mbar 9 The pressure can be adjusted ifrequired 10 To check and set minimum pressure first remove one of the modulator wires Adjusting the Pressure Fig39 11 Remove the plastic protection cap from the pressure adjustment nuts on the valve 12 The smaller nut 5mm adjusts minimum pressure and the larger nut 8...

Page 27: ...on that are relevant to the appliance 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 subsequent regular service visit recorded 4 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with I S 813 An example of this is given in I S 813 Domestic Gas Installations Th...

Page 28: ...outercase panel so that its securing tabs are clear of the facia Remove the panel Fig 41 6 Remove the screws securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case Fig 43 7 Note the positions of the three wires on the fan motor and remove them Remove the sensing tube from the fan spigot Fig 42 8 Slacken the screws on the fan spigot outlet pipe clamp...

Page 29: ...at exchanger fins are clear of any obstruction NOTE If necessary the secondary heat exchanger may be dismantled see section 12 23 D H W Filters Fig 48 17 If the flow of domestic hot water is diminished it may be necessary to clean the filters 18 Initially check the cold water inlet tap filter 19 Turn the tap off Undo the blanking cap and remove the threaded bush Fig 47 20 Extract the filter and ri...

Page 30: ...the baffle from the slot in the fan hood 5 Undo the screws securing the fan hood to the appliance back panel and draw the fan and hood assembly forwards 6 Remove the screws and spring washers securing the fan to the hood Transfer the flue spigot outlet pipe to the new fan 7 Fit the new fan to the hood using the screws and spring washers previously removed 8 Reassemble in reverse order of dismantli...

Page 31: ...e side insulation carriers engage in the slots in the heat exchanger side plates 5 Reassemble in reverse order of dismantling and repressurise the system 12 4 Burner Fig 53 1 Remove the four screws securing the combustion box door and remove the door 2 Draw the burner out of the combustion box pulling the electrode grommets from the slots in the combustion box lower panel 3 Disconnect the electrod...

Page 32: ...de being replaced Undo the securing screw and withdraw the electrode to the burner 4 Reassemble in reverse order 12 7 Insulation Fig 55 1 Remove the four screws securing the combustion box door and remove the door 2 Slide the side insulation pieces carefully out of their carriers 3 To replace the rear insulation piece it is necessary to remove the heat exchanger as described in Section 12 3 and sl...

Page 33: ...those securing the outlet manifold to the burner manifold 6 Remove the valve from the boiler 7 Note the orientation of the inlet pipe and outlet manifold Undo the securing screws and remove the pipe and manifold 8 Examine the 0 ring seals for damage replacing as necessary 9 Fit the inlet pipe and outlet manifold to the new valve ensuring that the 0 ring seals are in place 10 Reassemble in reverse ...

Page 34: ...atic air vent from the pump body Undo the two screws securing the body to the pipe and manifold and draw the pump forwards 2 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 3 Connect the wiring to the new pump Examine the 0 ring seals on the return pipe ...

Page 35: ...n the system return pipe as close as possible to the boiler 2 Drain the system and undo all gas water and condensate drain connections Remove the flue elbow 3 Lift the boiler off the wall bracket and lay it on it s side on a clean flat surface 4 Undo the nut on the vessel outlet spigot and remove the locknut and spring washer securing the spigot to the boiler chassis 5 Undo the screws and remove t...

Page 36: ... P C B and disconnect them Pull the drive pins off the P C B 4 Undo the securing screws and remove the P C B 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 12 19 Selector Switch Fig 67 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo the screws securing the control box cover and relea...

Page 37: ...owards the centre more than the right hand one 7 Reassemble in reverse order 12 21 Diverter Valve Assembly Fig 69 The diverter valve assembly comprises of a central heating pressure differential valve and a domestic hot water pressure differential valve These are connected to a manifold which is joined to the plate heat exchanger DHW Pressure Differential Valve Fig 70 1 Drain the primary circuit 2...

Page 38: ...ine the diaphragm hold the assembly securely and carefully remove the four screws The diaphragm spring will force the two halves of the valve apart 8 Carefully examine the diaphragm and replace it if there is any damage 9 Reassemble in reverse order CH Pressure Microswitch Fig 71 1 Remove the two wires from the pressure microswitch 2 Undo the screw securing the microswitch bracket to the valve bod...

Page 39: ...cken the screws on the fan spigot outlet pipe clamp Ease the clamp to the left Undo the screw at the left hand end of the pipe 5 Remove the nut securing the elbow to the secondary heat exchanger Draw the elbow and outlet pipe forwards 6 Remove the secondary heat exchanger from the outer drum by easing it forward 7 Reassemble in reverse order of dismantling 12 24 Flue Overheat Thermostat Fig 74 NOT...

Page 40: ...bk br b I I I M4 i I I I I IFA2 M1 4 bk Control PCB M2 M7 Flame Sensing Electrode br bk b brown black blue red yellow green I yellow white grey Y g y w gr On Off Reset Selector Switch Temperature Sensor Hydraulic Differential Pressure Switch Flue Thermostat b b Safety Thermostat T bk I L bk L br bk bk bk 31 b II 27 l eo br M5 ...

Page 41: ...Flue Overheat Thermostat 5112395 371 40 63 E66 411 Spark or Sensing Electrode 247384 72 Pump Complete 248042 101 E66 432 Hydraulic Outlet Assembly 248061 102 E66 434 Valve 3 WayAssembly 248062 23 103 343619 Pressure Differential Assy 248063 22 Fan 23 Pressure Switch 32 Heat Exchanger 41 Burner 44 E66402 Injector 1 18NG 59 E66 408 Electrode Lead 131 Temperature Sensor 135 E66 697 Safety Limit Therm...

Page 42: ...luminated YES Turn IJ thermostat to max Pump runs YES Air pressure switch proved YES Spark at ignition electrodes for up to 10 seconds YES Burner on h neon illuminated YES Burner extinguishes after 10 seconds NO Burner output modulates until set temperature is reached NO NOTE When instructed to turn the Selector to the reset position turn the Selector Switch fully anticlockwise against the spring ...

Page 43: ... Turn If thermostat to max Pump runs YES Air pressure switch proved YES Spark at ignition electrodes for up to 10 seconds YES I j Burner on h neon illuminated YES Burner extinguishes after 10 seconds NO Burner output modulates until set temperature is reached NO Go to section A Go to section B YES NO External controls and where fitted integral timer calling for heat NO Go to section c Turn the sel...

Page 44: ...xchanger If modulation does not occur go to section G YES DHW flow valve senses no flow Primary water diverted to CH system DHW flow switch released off YES NO Diverter valve spindle assembly faulty Fan stops 15 0 FAULT FINDING YES Replace DHW flow microswitch Replace PCB Go to section J L 0 Turn the selector to the reset position If the light does not extinguish go to section H K Pump stops Opera...

Page 45: ... INO IReplace PCB YES c 1 ICH system pressure 0 5 to 1 5 bar NO I Re pressurisesystem I IOpen the automatic air vent I 2 NO Check the tap of the automatic air vent is opened 3 Primary flow valve diaphragm damaged NO YES Replace diaphragm Flow valve rod obstructed D 1 Continuity across flow microswitch and PCB M2 connector terminals 3 4 NO IReplace microswitch I 2 Primary temperature sensor faulty ...

Page 46: ...k and correct if necessary 1 Ignition electrode and lead 2 Electrode connection 3 Spark gap and position 230V at Main PCB M4 NO I ReplacePCB I connector across terminals 37 38 Check wiring YES I Replace gas valve electrical plug igniter assy 44 1 Check the burner setting pressure of the gas valve see Section 9 2 of Commissioning 2 Voltage at modulating coil of gas valve is Max burner press approx ...

Page 47: ...ontinuity across terminals 1 a of ON OFF RESET selector when turned to Reset position YES L Press the reset button on the flue overheat thermostat If the boiler does not relight or repeatedly cuts out check the operation of the flue system or replace the flue overheat thermostat If the flue overheat thermostat has not been activated see section D Ensure that mains input terminal L is Live 230V and...

Page 48: ... m3 hr 0 N A FORCOMBINATION BOlliERS ONLY HASAWATER SCALE REDUCER BEEN FITTED WHAT TYPE OFSCALE REDUCER HASBEEN FITTED FORTHEDOMESTIC HO rWATIlR MODE MeASURE RECORD GASRATE MAXIMUM BURNER OPERATING PRESSURE IFAPPLICABLE COLD WATER INLET TEMPERATURE HOTWATER OUTLET TEMPERATURE WATER FLOW RATE I m3 hr 0 N A FORCONDENSING BOILERS ONLY CONFIRM THE FOLLOWING _ THECONDENSATE DRAIN HASBEEN INSTALLED INAC...

Page 49: ...RE Ak SERVICE 5 DATE ENGINEER NAME COMPANY NAME TELNo CORGIID CARD SERIAL No COMMENTS SERVICE 6 DATE ENGINEER NAME COMPANY NAME TELNo CORGIID CARD SERIAL No COMMENTS SIGNATURE SIGNATURE _ SERVICE 7 DATE ENGINEER NAME COMPANY NAME TELNo CORGIID CARD SERIAL No COMMENTS SERVICE8 DATE ENGINEER NAME COMPANY NAME TELNo CORGIID CARD SERIAL No COMMENTS SIGNATURE l SIGNATURE _w _w SERVICE9 DATE ENGINEER NA...

Page 50: ...ly 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 said subject to our standard Conditions of Saie which are available on request MAIN BAXI POTTERTON A Trading Division of Saxi Heating UK LId Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN After Sales Service 08701 65...

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