Potterton WH 46 Installation, Operation And Maintenance Manual Download | Manualshive

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WALL-MOUNTED CONDENSING BOILERS

WH 46

WH 65

0085

GB

IE

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

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Summary of Contents for WH 46

Page 1: ...WALL MOUNTED CONDENSING BOILERS WH 46 WH 65 0085 GB IE INSTALLATION OPERATION AND MAINTENANCE MANUAL ...

Page 2: ...Instructions prior to installation 3 2 Instructions prior to commissioning 3 3 Commissioning of the boiler 4 4 Filling the boiler 10 5 Turning off the boiler 10 6 Prolonged standstill of the system Frost protection 10 7 Servicing instructions 10 8 General information 11 9 Instructions prior to installation 11 10 Boiler installation 12 11 Boiler size 13 12 Installation of flue and air ducts 13 13 H...

Page 3: ... and flushed out thoroughly to eliminate residual thread cutting swarf solder and solvents if any using suitable proprietary products To avoid damaging metal plastic and rubber parts use only neutral cleaners i e non acid and non alkaline The recommended products for cleaning are SENTINEL X300 or X400 and FERNOX heating circuit restore The use of this product must be strictly in accordance with th...

Page 4: ...me present on Outdoor temperature Standby off Operation in manual mode at minimum tem perature Operation in manual mode at the maximum temperature set Operation in automatic mode Operation in central heating mode Operation in hot water mode IMPORTANT The instructions contained in this manual relating to the operation of the hot water circuit are relevant only if the appliance is actually connected...

Page 5: ...it this function which is identified by the appearance on the display of two black dashes under the symbol 4 Reset key In case of a fault referred to in point 3 7 Faults and resetting the boiler the boiler can be restarted by pressing this key for at least two seconds If this key is pressed with no fault present the display will show the message E153 and the same key has to be pressed again for at...

Page 6: ...d the key 2 figure 1 can be used to shift the central heating curve Press the keys to decrease or increase the room temperature in the premises to be heated 3 3 SETTING THE MAXIMUM CENTRAL HEATING TEMPERATURE Press the key 3 figure 1 to set the maximum hot water temperature Press the keys to set the temperature required Press either of the keys 1 or 10 figure 1 to save and return to the main menu ...

Page 7: ...ied by the factory the appliance is set up with the hot water function always enabled and the do mestic hot water programming function disabled The instructions for enabling this program are given in chapter 17 which is addressed specifically to installers parameter H91 If the program is enabled program lines from 31 to 36 must be set up as described in heading 3 5 1 3 6 SETTING THE MINIMUM CENTRA...

Page 8: ...24 00 P35 Start of third daily period of hot water production 0 00 00 00 24 00 P36 End of third daily period of hot water production 0 00 00 00 24 00 P45 Reset of daily central heating and domestic hot water production programs factory settings Press the keys together for about 3 seconds the number 1 appears on the display Confirm by pressing either of the keys 0 0 1 Note Parameters from P31 to P3...

Page 9: ...higher than 95 C If this fault persists call the authorised service centre E128 Loss of flame during operation the ionization current has fallen below the limit Call an authorised service centre E129 Minimum fan speed limit is hurt Call an authorised service centre E132 floor thermostat tripped call the authorised service centre E133 no gas press the reset key for about 2 seconds if the fault pers...

Page 10: ...ic management of the boilers includes a frost protection function which operates the burner to reach a heating flow temperature of 30 C when the system heating flow temperature drops below 5 C The frost protection function is enabled if electrical supply to the boiler is on the gas service cock is open the system pressure is as required the boiler is not isolated To maintain efficient and safe ope...

Page 11: ...e correct operation of the appliance and avoid invalidating the warranty observe the following precautions 1 Hot water circuit If the water hardness is greater than 20 F 1 F 10 mg calcium carbonate per litre of water a polyphosphate or comparable treatment system responding to current regulations must be used 2 Heating circuit 2 1 New system Before proceeding with installation of the boiler the sy...

Page 12: ... exchanger Dose with inhibitor Failure to observe the above will render the guarantee null and void 10 BOILER INSTALLATION Decide upon the boiler location then tape the template on the wall Connect the pipework to the gas and water inlets prearranged on the template lower bar If you are either installing the boiler on a pre existing system or replacing it we suggest you also fit strainers on the s...

Page 13: ...iler thanks to the fittings and fixtures supplied de scribed below The boiler is especially designed for connection to an exhaust flue air ducting with either concentric vertical or horizontal terminal Where exhaust and intake flues not supplied by POTTERTON GOLD HIGH OUTPUT have been installed these must be certified for the type of use and must have a maximum pressure drop of 100 Pa for the comp...

Page 14: ... water leakages If the terminal is below 2m then a terminal gaurd is required Ensure a minimum downward slope of 3 towards the boiler A 87 bend reduces the total flue length by 1 metre A 45 bend reduces the total flue length by 0 5 metre HORIZONTAL CONCENTRIC FLUES Boiler Flue Size Number of Bends 90 1 2 3 4 WH46 Ø80 125 9 m 8 m 7 m 6 m WH65 Ø80 125 9 m 8 m 7 m 6 m VERTICAL CONCENTRIC FLUES Boiler...

Page 15: ...n it depends on the length of the flue par 12 in accordance with the installation of flue and air pipes as indicated in the tables below The factory set value is referred to the minimum length of flue pipe 0 4 m for concentric 0 20 m for twin To carry such updating changing the speed of the fan rpm at the maximum and minimum heat input refer to par 16 12 5 FAN RPM UPDATING DEPENDING ON FLUE LENGTH...

Page 16: ...ation Details Pumped heating circuits with remote control QAA73 or Room Thermostat including hot water tank without and with primary loop 13 1 HYDRAULIC SYSTEM 1 Figure 9a 0602_0704 CG1782 without low loss header optional extra Figure 9b 0602_0703 CG1756 with low loss header and primary loop optional extra ...

Page 17: ... supplied Applications pumps sensor remote control have to be connected to terminal as follows see also section 14 WITH QAA73 REMOTE CONTROL WITH ROOM THERMOSTAT APPLICATION TERMINAL BOARD TERMINAL BOARD PRIMARY PUMP PLP only for figure 9b M1 A B M1 A B DHW PUMP PDHW M3 13 14 M3 13 14 HEATING PUMP P1 M3 11 12 M3 11 12 DHW SENSOR TS M2 7 8 M2 7 8 REMOTE CONTROL QAA73 M2 1 2 NO ROOM THERMOSTAT M2 3 ...

Page 18: ...hermostat B9 Temperature Sensor QAC34 Zone Controller Clip in AGU2 500 FS Flow Sensor QAD36 supplied with AGU2 500 P1 Heating Pump P DHW Hot Water pump PLP Primary Pump 3WV 3 way Valve power open power close Available Optional Extra Pumps Not Supplied Isolating Valve Not Supplied Installer Wiring Hot Water Cylinder Not Supplied Low Loss Header Not Supplied Non Return Valve Not supplied Figure 10 0...

Page 19: ...ol have to be connected to terminal as follows see also section 14 Parameter changes requires see also section 16 PCB PARAMETER Description Setting Parameter H552 Hydraulic system H552 50 H553 KonfigHKS H553 12 H615 KonfigAusgang H615 9 H632 Wanfo Q8 H632 00001111 13 3 HEAT EXCHANGER PRESSURE DROP Boiler Hydraulic Resistance and Water Flow Rates 11 C T 15 C T 20 C T 30 C T kPa Lit sec kPa Lit sec ...

Page 20: ... correct Use a double pole switch isolator with a contact separation of at least 3mm in both poles In case you replace the power supply cable fit a HAR H05 VV F 3x0 75mm2 cable with an 8mm diameter maximum outer sheath The fuse a fast acting type rated 2A is incorporated into the power supply terminals remove the black fuse holder to enable inspection and or replacement IMPORTANT Check that the ov...

Page 21: ...ferring to its hydraulic resistance table Terminals M3 11 12 connection for heating pump P1 Terminals M3 13 14 connection for hot water tank pump PDHW The electrical specifications of the pump must be as follows 230 V AC 50 Hz 1 A max cos f 0 8 If the specifications of the installed pump are different a relay must be wired between the boiler control circuit board and the pump It is advisable not t...

Page 22: ...ccessory The sensing element of the NTC device must be located in the recess provided on the storage tank figure 13 The temperature and on off programming of the domestic hot water supply are selected directly from the boiler control panel as described in this manual under the user instruction headings 14 2 CONNECTING THE HOT WATER TANK SENSOR Figure 13 0602_0707 CG1764 SAFETY CONTACT ROOM THERMOS...

Page 23: ... no voltage across the ends of the two thermostat connection wires Terminals 5 6 external safety contact low voltage Terminals 7 8 connection of SIEMENS model QAC34 outdoor temperature sensor supplied as optional extra Read the instructions supplied with this accessory for correct installation procedures Terminals 9 10 connection of hot water temperature sensor supplied as optional extra for conne...

Page 24: ...Press the information button i to quit programming 14 4 CONNECTING THE QAA73 TEMPERATURE REGULATOR fault messages In the event of fault the display panel on the QAA73 shows the flashing symbol Press the information key to display the error code and a description of the fault see Fault warning tables on paragraph 3 9 Line no Parameter Range Default value 70 HC1 curve Selection of central heating ci...

Page 25: ...ing parameter H532 as described in section 16 setting the boiler parameters See graph 2 for selecting the curve referred to a room temperature of 20 C The chosen curve can be shifted by pressing the 2 button 2 on the boiler control panel and modifying the value displayed by pressing the and keys See graph 3 for curve selection The example show in graph 3 refers to the curve Kt 15 Increase the valu...

Page 26: ...described in section 14 4 QAA73 parameters which can be set by the installation engineer service See graph 4 for selecting the curve referred to a room temperature of 20 C The curve is shifted automatically on the basis of the room temperature set using the QAA73 climate con trol If the system is divided into zones the temperature curve kt relating to the part of the system not control led by the ...

Page 27: ...for measurement of the OFFSET Pl Air signal input from fan V Gas flow adjuster screw max fire K OFFSET adjuster screw min fire 0310_0114 Figure 15 15 GAS VALVE ADJUSTMENT Carry out the following ope rations in the given sequence 1 Calibration of the maximum heat output Check that the CO2 measured on the flue with the boiler operating at the maximum heat output is the same as that shown in table 1 ...

Page 28: ...G20 2H 20 mbar G31 3P 37 mbar CO2 max heat output 8 7 10 CO2 min heat output 8 4 9 8 IMPORTANT in the case of conversion from natural gas to propane LPG the following operations must be performed before calibrating the gas valve as illustrated previously Turn adjuster screw V on the gas valve through the number of complete revolutions specified in table 3 Gas consumption at 15 C 1013 mbar gas G20 ...

Page 29: ... heating circuit HC2 of a system with more than one zone corresponding to the circuit of the low temperature zone if the SIEMENS AGU2 500 accessory is used 80 H516 Automatic Summer Winter switching temperature C 20 H532 Selection of temperature curve of central heating circuit HC1 see Graph 1 15 H533 Selection of temperature curve of central heating circuit HC2 see Graph 1 15 H536 Maximum speed at...

Page 30: ... then press the reset button on the boiler It is forbidden to disable this safety device Flame ionization detector The flame sensing electrode guarantees safety of operation in case of gas failure or incomplete interlighting of the main burner Under such conditions the boiler is locked out You must press the reset button on the boiler to restore the normal operating conditions Supplementary pump o...

Page 31: ...to the exhaust flue duct to allow measurements of the combustion products and efficiency The second test point is connected to the comburant air inlet duct to check possible combustion products circulation in case of coaxial ducts The exhaust flue duct test point allows measurements of the following combustion products temperature concentration of oxygen O2 or alternatively of carbon dioxide CO2 c...

Page 32: ...tons to exit the function To ensure the boiler operates at peak efficiency the following checks must be performed every year Check on the appearance and tightness of the gas and combustion circuit gaskets Check on the condition and position of the ignition and flame sensing electrodes see section 18 Check on the condition of the burner and its fixing to the aluminium flange Check for any dirt in t...

Page 33: ...C overheat thermostat 6 Gas valve 7 Heat exchanger 8 Flame detector electrode ionisation probe 9 Main burner 10 Ignition electrode 11 Air gas mixture header 12 Mixer with venturi 13 Injector 14 Fan 15 Flue thermostat 16 Flue spigot 17 Automatic air vent 18 Flue joint 19 Hydraulic pressure sensor 20 Pressure gas switch 21 NTC return heating probe 22 BOILER SCHEMATIC Figure 20 ...

Page 34: ...34 INSTRUCTIONS PERTAINING TO THE INSTALLER 926 772 1 GB IE 23 ILLUSTRATED WIRING DIAGRAM ...

Page 35: ... air duct diameter mm 125 125 Twin pipe flue duct diameter mm 80 80 Twin pipe air duct diameter mm 80 80 Max flue mass flow rate kg s 0 022 0 032 Min flue mass flow rate kg s 0 007 0 010 Max flue temperature C 74 75 NOx class 5 5 NOx mg kWh 38 4 37 7 Type of gas used G20 G31 G20 G31 Natural gas pressure 2H mbar 20 20 Propane gas pressure 3P mbar 37 37 Gas Consumption NG m3 hr 4 91 7 08 Gas Consump...

Page 36: ...s contained herein at any time and without previous warning These Instructions are only meant to provide consumers with use information and under no circumstance should they be construed as a contract with a third party Wood Lane Erdington Birmingham B24 9QP TELEPHONE 0845 0701058 FAX 0845 0701059 WEB www pottertongold co uk POTTERTON GOLD HIGH OUTPUT ...

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