Potterton Combi 80 Installation & Service Instructions Manual Download | Manualshive

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Combi 80 Installation & Service Instructions

About the Boiler

See inside cover for models covered by these instructions.
This is a wall mounted, fanned, room sealed combination boiler.
This boiler is for use with Natural Gas (G20) Only at 20 mbar and for use in GB & IE.

About Safety

The Gas Safety (Installation and Use) Regulations 1998.

‘‘In your own interest, and that of safety, it is law that all gas appliances are installed by
competent persons, in accordance with the above regulations. Failure to install
appliances correctly could lead to prosecution.’’

Installation must be in accordance with the User, Installation & Servicing Instructions and
the rules in force.

Polythene bags used for packaging are a potential hazard to babies and young children
and MUST BE CAREFULLY DISPOSED OF IMMEDIATELY.

Leave these instructions with the user for use on future calls.

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Summary of Contents for Combi 80

Page 1: ...1998 In your own interest and that of safety it is law that all gas appliances are installed by competent persons in accordance with the above regulations Failure to install appliances correctly could lead to prosecution Installation must be in accordance with the User Installation Servicing Instructions and the rules in force Polythene bags used for packaging are a potential hazard to babies and ...

Page 2: ... Remove the Burner 24 4 9 Gas Pressure Adjustment 24 4 10 The Central Heating Sealed System 24 4 11 Other Components 24 5 Replacement of Parts 26 5 1 Central Heating Overheat Thermostat 27 5 2 Dom H Water Limit Frost Thermostat 27 5 3 Sensor and Ignition Electrode 27 5 4 Sensor and Ignition Leads 27 5 5 Burner 27 5 6 Injectors 27 5 7 Gas Valve 28 5 8 Modulating Valve 28 5 9 First Solenoid Valve 28...

Page 3: ...in accordance with The Gas Safety Installation Use Regulations 1998 and the current issue of The Building Regulations Building Standards Scotland Regulations Local Building Regulations Model Local Water Undertaking Bye Laws I E E Regulations Health and Safety Document No 635 The Electricity at Work Regulations 1989 BS 6891 BS 6798 BS 5449 BS 5546 BS 5440 1 BS 5440 2 BS 7593 BG DM2 Samples of the C...

Page 4: ... dust levels are only likely to arise following harsh abrasion In general normal handling and use will not present high risk follow good hygiene practices wash hands before touching eyes consuming food drinking or using the toilet First Aid Medical attention must be sought following eye contact or prolonged reddening of the skin Heat Exchanger Material Copper with lead tin coating Description Finn...

Page 5: ... Pipework from the meter to the combination boiler must be of an adequate size Do NOT use pipes of a smaller size than the combination boiler inlet gas connection 15mm The complete installation must be tested for gas soundness and purged as described in BS 6891 1 2 Electrical Supply Wiring external to the appliance MUST be in accordance with the current I E E Regulations for Electrical Installatio...

Page 6: ...Installation Requirements Page 6 Fig 3 ...

Page 7: ...tailed guidance on this aspect Clearances around the Appliance Fig 4 Side Clearance For operation and servicing 25 mm each side Top Clearance A minimum of 160 mm but 300 mm is preferred to allow removal of the central heating expansion vessel without removing the appliance from the wall if replacement is required Bottom Clearance A bottom clearance of 220 mm is required between the appliance and a...

Page 8: ...mbustion discharging from the terminal cannot re enter the building or any other adjacent building through ventilators windows doors natural air infiltration or forced ventilation air conditioning If products of combustion are found to be re entering any building the appliance MUST be turned OFF IMMEDIATELY POSITION MIN DISTANCE mm A DIRECTLY BELOW AN OPENABLE WINDOW AIR VENT OR ANY OTHER VENTILAT...

Page 9: ...this will cause the appliances to overheat and go to lockout The installation should be designed to work with flow temperatures of up to 90 C All components of the system must be suitable for a maximum pressure of 3 bar 45 psi and a temperature of 110 C The following components are incorporated within the appliance a Circulating pump b Diverter valve c Pressure Relief valve with a non adjustable p...

Page 10: ...0 litres 2 7 5 4 8 2 10 9 13 6 16 3 19 1 21 8 24 5 27 2 30 0 32 7 35 7 38 1 40 9 43 6 46 3 49 0 51 8 54 5 litres 3 9 7 8 11 7 15 6 19 5 23 4 27 3 31 2 35 1 39 0 42 9 46 8 50 7 54 6 58 5 62 4 66 3 70 2 74 1 78 0 For system volumes other than those given above multiply the system volume by the factor across 0 109 0 156 Table 2 Expansion Vessel Requirements Deduct from the value given in the table th...

Page 11: ...s from the system by re pressurisation of the system Reference should be made to British Gas Publications Material and Installation Specifications for Domestic Central Heating and Hot Water Pump Performance Curve The circulating pump fitted within the appliance should be capable of satisfying most system requirements For central heating systems greater than 15 kW it may be necessary to use a highe...

Page 12: ...oiler is being fitted as a replacement to an existing system it is best practice to clean the system prior to fitting the new boiler In this case BetzDearborn Sentinel X400 or Fernox Superfloc should be used In order to minimise corrosion in the system inhibit scale formation and microbiological growth we recommend that an inhibitor is added to the system when it is refilled following the final ho...

Page 13: ...s from the pipes a small quantity of water may be present 6 At this point follow the Installation Instructions supplied with the Flue System then proceed as follows 7 Boiler Connections All connections to the appliance are supplied unassembled in the boiler carton on a vacuum formed card Remove all fittings and assemble to the appliance Note When fitted the Red levered central heating tail C H flo...

Page 14: ... This should be fitted down stream of the appliance 2 4 C H Water Connections 1 Before any central heating connections are made to the combination boiler all system valves should be opened and the system thoroughly flushed out with cold water 2 Connect the central heating return pipe to the isolating cock identified by a Blue lever right hand of the two pipes 3 Connect the central heating flow pip...

Page 15: ... thermostat If no room thermostat is to be fitted retain link wire If a programmable room thermostat is to be used it must be fitted in place of the external timer and the link between 3 4 retained If the installation does not have an internal or external timer the central heating switch on the front of the appliance must be set to Constant during periods when central heating is required If using ...

Page 16: ... installation including the meter should be inspected and tested for soundness and purged in accordance with the recommendations of BS 6891 Purging air from the gas line may be carried out by loosening the union on the gas service cock and purging Re tighten the union when completed and check for gas soundness N B Open all doors and windows extinguish naked lights and DO NOT SMOKE when carrying ou...

Page 17: ...the gauge clockwise Check the pump spindle is free to rotate by unscrewing the black octagonal nut withdraw to engage the motor spindle The knob should rotate freely The pump will normally self vent the air from the rotor chamber within a short while of switching on however should manual venting of the bearings be required sideways pressure should be applied and maintained to the knob until a smal...

Page 18: ...tlet and ve connection to the base of the inner casing as described in Section 3 3 Set the pressures to the values in Table 3 by adjusting the gas valve in the following manner Note It is important to note the order in which the maximum and minimum pressures are set The maximum pressure must always be set before adjustment of the minimum pressure Adjusting the Maximum Pressure Fig 12 i Cut off cab...

Page 19: ...oss of gas supply flame failure or over heating of the central heating water will cause the appliance to shut down or Lockout This will be indicated by the lockout light being illuminated To Reset the appliance press the RESET button on the front panel and hold in that position for 10 seconds and release The appliance should now operate normally If this is not the case refer to the Fault Finding g...

Page 20: ...hutting down procedures 3 Demonstrate the operation of the boiler including the use and adjustment of all system controls This then ensures the greatest possible fuel economy consistent with household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperativ...

Page 21: ... attention must also be paid to the heating and hot water systems in the property with special attention to radiator valves thermostats clocks leaking hot water taps etc Where it is necessary to replace a gasket that relies on adhesive for securing this adhesive will be supplied with the gasket in the spares kit Prior to servicing Remove the white front case see Section 4 1 on Page 22 Operate the ...

Page 22: ...s and lifting the panel clear of the two lower retaining flanges Ensure the insulation remains in position The underside of the heat exchanger is now exposed 4 7 To Inspect and Clean the Boiler Fig 14 1 Inspect the heat exchanger for any blockage Deposits of any material should be brushed away using a soft brush Note Do not use brushes with metallic bristles 2 Examine internal pipe work connection...

Page 23: ...Servicing Routine Maintenance Page 23 ...

Page 24: ...wise to show the system pressure If the black indicator shows a lower pressure than the red indicator the system has lost pressure and should be re pressurised The correct procedures are shown in the installation section See permissible methods of filling Page 11 4 11 Other Components No further servicing is required on any other appliance components It may occasionally be necessary to replenish t...

Page 25: ...Servicing Routine Maintenance Page 25 ...

Page 26: ...e made Isolate the Gas The supply should be isolated at the boiler gas service cock one quarter turn of square spindle Isolate Drain the Water When draining and removing water carrying components ensure that the control box is suitably protected from accidental damage Central Heating Reduce system pressure at an external drain tap then close the isolating valves at the boiler Remove the drain scre...

Page 27: ...See 4 1 to 4 3 4 6 in Routine Maintenance 2 Disconnect the lead from the base of the electrode to be changed Remove the electrode retaining screw and remove the electrode from the burner 3 Fit new electrode and re assemble in reverse order checking the gap measures 4mm 0 5mm Fig 14 5 4 Sensor and Ignition Leads 1 Remove the white front case base panel and main air box cover See 4 1 to 4 3 in Routi...

Page 28: ...stic cover by cutting off the nylon tie twisting the cover anti clockwise 90 and levering off with a small screwdriver 4 Using a 14 mm spanner unscrew the complete inner cartridge and remove with niting plate 5 Lift off the solenoid coil and remove from metal bracket 6 Replace in reverse order ensuring the notch in the niting plate is located over the raised pip on the new solenoid coil 7 Reconnec...

Page 29: ...Replacement of Parts Page 29 Fig 18 ...

Page 30: ... case and base panel See 4 1 4 2 in Routine Maintenance i USER DISPLAY BOARD 1 Undo the fixing screw retaining the facia panel and swing the panel downwards 2 Remove the plug connector s from the rear of the board and undo the four securing screws 3 Replace board and re assemble in reverse order ii MODULATION CONTROL BOARD Note The board has a replaceable fuse rated at 2A 1 Undo the fixing screw r...

Page 31: ... seal by pulling the seal away from the fluehood and disconnecting the pop in locaters 3 Fix the new seals in position 4 Re assemble in reverse order Ensure the seal is not trapped on the turned down edge 5 17 Temperature Sensor D H W C H Fig 11 1 Remove the white front case and base panel See 4 1 4 2 in Routine Maintenance 2 For D H W sensor lower the control panel assembly by undoing the securin...

Page 32: ...ling and save time as the motor assembly may well need to be removed from the new pump to correctly position the electrical control box 1 Remove the white front case and base panel See 4 1 4 2in Routine Maintenance 2 Lower the control panel assembly by undoing the securing screw at the top right hand side of the control panel 3 Unplug the pump wiring at the in line connector 4 Drain the central he...

Page 33: ...ating valve to drain the system 4 Drain the central heating circuit as described on Page 26 5 Undo the two D H W pipe connections to the valve head Retain the two pipe seals 6 Unscrew the two grub screws 2 mm hexagon key which hold the head to the main body Pull the head forwards using a twisting action and carefully remove the head Note the position of the loose brass cylinder on the wax capsule ...

Page 34: ...ed and corrected if necessary The pressure should be at least equal to the system pressure at the appliance 8 Fit the new expansion vessel and re assemble in reverse order Ensure that the vessel is located correctly in the lower support bracket Route the flexible pipe through the hole in the back panel and refit grommet Procedure 2 If the clearance above the appliance is less than 300 mm the appli...

Page 35: ...ks 5 25 Heat Exchanger Fig 14 1 Perform 4 1 to 4 6 4 8 in Routine Maintenance Remove the combustion chamber insulation by removing each side panel retaining screw and pulling the complete side panel insulation assembly forwards The rear insulation can remain in situ 2 Drain the appliance as described on Page 26 Undo the heat exchanger connection to the auto air vent pipe 3 Disconnect the electrica...

Page 36: ...sealing washer ensuring the air vent cap is left loose Re assemble in reverse order ensure that the grommet is correctly positioned Re charge the system as described in Section 1 8 and check for leaks 5 27 Pressure Relief Valve Fig 25 1 Remove the white front case and base panel See 4 1 4 2 in Routine Maintenance 2 Drain the central heating circuit as described on Page 26 3 Undo the outlet tube nu...

Page 37: ...ontrol board PL 6 top right hand side of control board Thread the wiring out of the control panel 4 Remove the two screws retaining the transformer to the back panel and remove transformer from appliance 5 Fit the new transformer assembly in reverse order 5 29 Sight Glass With Securing Frame 1 Remove the white front case base panel and air box main cover See 4 1 4 2 4 3 in Routine Maintenance 2 On...

Page 38: ... Boiler Switch to Standby b Set Heating switch to OFF Centre c Turn OFF all Hot Water Taps d Ensure all Isolating Valves at base of appliance are OPEN e Turn ON EXTERNAL GAS and ELECTRICAL Supplies f Arrange for system controls to be calling for heat ...

Page 39: ...7 Electrical Layouts Page 39 Control Flow Sequence ...

Page 40: ...Functional Flow Page 40 ...

Page 41: ...Electrical Diagram Page 41 ...

Page 42: ... Water Content C H 1 85 litres Gas Supply Connection 1 2 B S P F Gas Cock Inlet Connection D H W 15 mm Compression Isolating Valve Outlet Connection D H W 15 mm Copper Pipe Flow Connection C H 22 mm Compression Isolating Valve Return Connection C H 22 mm Compression Isolating Valve Safety Discharge Pipe 15 mm Copper Pipe C H Sealed System Maximum Operating Pressure 2 5 bar36 3 lb in Minimum Operat...

Page 43: ...9 Optional Extras Page 43 ...

Page 44: ...Optional Extras Page 44 ...

Page 45: ...Optional Extras Page 45 ...

Page 46: ...10 Short List of Spares Page 46 ...

Page 47: ...Pressure Gauge 1 929644 289 531 11 Burner Injector Bray 2 46mm 3 22 20207 12 Air Flow Switch Honeywell C6065A1093 1 642212 379 350 13 Diverter Valve Assembly Complete 1 929651 289 718 14 Wax Capsule Assembly 1 929803 289 741 15 D H W Flow Switch 1 929673 289 724 16 Fan Assembly 1 929501 379 342 17 Electrode Lead Assembly 1 929551 289 479 18 Detection Lead Assembly 1 929552 289 480 19 D H W C H Tem...

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