Potterton Gold H 15 Installation & Service Instructions Manual Download

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Installation & Service Instructions

These instructions include the Benchmark Commissioning

Checklist and should be left with the user for safe keeping.

Gold H

Range

Condensing

Boiler

You can rely on

Summary of Contents for Gold H 15

Page 1: ...ing UK Ltd 2012 Installation Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Gold H Range Condensing Boiler You can rely on ...

Page 2: ...ating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information Building Regulations and the Benchmark Commissioning Checklist Building Regulations England Wales require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department From 1 April 2005 this can be achieved via a Competent P...

Page 3: ...elevant LABC You must ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www gassaferegister co uk within 10 days If you notify via the Gas Safe Register the register will issue the Building Regulations certificate on members behalf Complete the Benchmark Checklist Instal...

Page 4: ...stallations NOTE The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty In GB this could also infringe the Gas Safety Installation and Use Regulations Warning Check the information on the data plate is compatible with local supply conditions Codes of Practic...

Page 5: ...oute is clear and unobstructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep your back straight bend your knees Don t twist move your feet avoid bending forwards and sideways and keep the load as close to your body as possible Where possible transport the boiler using a...

Page 6: ... 0 System Details 12 7 0 Site Requirements 16 8 0 Flue Options 22 9 0 Plume Displacement 27 10 0 Installation 31 11 0 Electrical 37 12 0 Commissioning the Boiler 39 13 0 Fitting the Outer Case 41 14 0 Servicing the Boiler 42 15 0 Changing Components 45 16 0 Short Parts List 51 17 0 Fault Finding 52 Benchmark Checklist 58 Section Page Contents 6 ...

Page 7: ...led with one of the purpose designed flues such as the standard horizontal flue kit part no 236921 1 2 Important Information Man made mineral fibre Some component parts of this appliance insulation pads gaskets and rope seals are manufactured from man made mineral fibre Prolonged or excessive exposure to this material may result in some irritation to the eyes skin or respiratory tract It is advisa...

Page 8: ...ection Thermostat 7 Fan Assembly 8 Condensate Trap 9 PCB Housing Assembly 10 Gas Service Cock 11 Gas Air Ratio Valve 12 Flow Pipe Connection 13 Return Pipe Connection 14 Flow Temperature Safety Thermostat Black 15 Flow Temperature Thermistor Red 16 Flow Switch dry fire protection 1 2 3 4 5 6 7 9 8 10 11 15 14 12 13 16 Fig 4 Fig 3 Fig 5 Fig 6 ...

Page 9: ...and thereby the gas rate to achieve optimum operation If the flow temperature is greater than the set point or the TRVs all shut down then fan post purge occurs 6 Fan Post Purge The pump and fan are on while the spark generator and gas valve are off After 5 seconds if the TRVs are not shut down then pump overrun occurs After 5 seconds if the TRVs are shut down then anti cycle occurs 7 Pump Overrun...

Page 10: ...in Front For Servicing 500mm Min Front In Operation 5mm Min 0 10 20 30 40 20 40 60 80 100 120 140 160 180 200 220 Water Flow Rate litres min Pressure Drop mbar 8 17 25 33 42 50 58 66 75 83 91 Pressure Drop in wg Hydraulic Resistance Chart Appliance Type C13 C33 C53 Nox Class 5 Heat Output P Condensing 40 C Mean Water Temp Max Min 15 model kW 16 49 10 1 18 model kW 19 27 24 model kW 23 8 10 1 Water...

Page 11: ...bove 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 The 1 5 fall provided by the elbow is to allow condensate to run back to the boiler for disposal through the condensate discharge pipe Flue length Y up to 1m 1m 2m 2m 3m Clearance X 27 5mm 55mm 82 5mm 360 Orientation Tube Ø 110mm D C B A E F Y At Least 1 5 X At Least 1 5 Fig 7 Fig...

Page 12: ...udge accumulates within the system risking damage to pump and valves boiler noise and circulation problems When fitting new systems flux will be evident within the system which can lead to damage of system components All systems must be thoroughly drained and flushed out using for example Sentinel X300 or X400 or Fernox F3 They should be used following the flushing agent manufacturer s instruction...

Page 13: ...be fitted on the flow c The pump must be fitted in accordance with the pump manufacturer s instructions d The open vent pipe must be taken up from a tee in a horizontal section of the flow pipe An alternative Low Head Installation Fig 12 2 For heads below 400mm then a combined vent and feed pipe may be connected This must be a minimum of 22mm diameter It is recommended that an air separator is fit...

Page 14: ...L N CH on HW on HW off L N E L N P F E b g y w o gr 1 C 2 g y S Plan Valve Cylinder Stat Room Stat Boiler Pump Timer 230V 50Hz L N E L N CH on HW on L N E L N P F E Motor S Plan Valve Motor o o gr b g y b gr br br Y Plan Diverter Valve Cylinder Stat Boiler Pump Timer 230V 50Hz L N E L N CH on HW on HW off L N E L N P F E b g y o gr 1 C 2 w g y S Plan Valve Cylinder Stat Boiler Pump Timer 230V 50Hz...

Page 15: ...ovided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment Your attention is drawn to for GB Guidance G24 2 and recommendation R24 2 of the Wat...

Page 16: ...de to the relevant requirements In GB this is the current I E E Wiring Regulations and Building Regulations In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the 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...

Page 17: ...ce is of adequate size to ensure correct operation Do not use pipes of a smaller diameter than the boiler gas connection 7 5 Electrical Supply 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 edition of ETCI rules 2 The mains supply is 230V 50Hz fu...

Page 18: ...diameter and must be supported using suitably spaced clips of the correct design to prevent sagging 6 It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres 7 Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe 8 External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external us...

Page 19: ... emptied then back pressure may force water out of the boiler trap and cause appliance lockout Boiler 2 5 Minimum fall iii Termination to a drain or gully Boiler 500mm min 2 5 Minimum fall iv Termination to a purpose made soakaway Holes in the soak away must face away from the building 50mm per metre of pipe run 50mm per metre of pipe run Further specific requirements for soakaway design are refer...

Page 20: ...ce Heating Element is NOT a substitute for correct installation of the condensate drain ALL requirements in this section must still be adhered to Boiler vi pumped into an external soil vent pipe 2 5 Minimum fall 50mm per metre of pipe run Condensate Pump Unheated Location e g Garage Basement or similar heated Boiler 2 5 Minimum fall 50mm per metre of pipe run Pipe must terminate above water level ...

Page 21: ... ensure the safe and nuisance free dispersal of combustion products Fig 17 Fig 16a 300 min Terminal Assembly TopView Rear Flue Property Boundary Line NOTE The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below Table 2 Terminal Position with Minimum Distance Fig 17 mm A1 Directly below an opening air bri...

Page 22: ...3 bend 1 0 m NOTE Flue length is measured from point X to Y as shown IMPORTANT All flue systems must be securely supported at least once every metre Suitable pipe supports are available as accessories X Y X Y 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...

Page 23: ...tal equivalent length for this example is 17 2 34 4 51 6 metres 1m extension 135 bend 91 5 bend 1m 1 3m 4 8m 5 2 2 5 0m 2 6m 9 6m AIR DUCT No of fittings pipes Sub total Equivalent Length Value Equivalent Length Air Duct 17 2m 1m extension 135 bend 91 5 bend 2m 2 6m 9 6m 5 2 2 10 0m 5 2m 19 2m FLUE DUCT No of fittings pipes Sub total Equivalent Length Value Equivalent Length Flue Duct 34 4m Y X C ...

Page 24: ...10mm 243014BAX T Vertical Flue Boiler Adaptor 5106888 S Flue Terminal Deflector 248167 FLUE GROUP P Twin Flue System 80mm diameter E Flue Extension 1000mm 246137 500mm 246136 250mm 246135 F Flue Bend pair 90 5121560 G Flue Bend 2 pair 135 5121561 J Vertical Flue Boiler Adaptor Kit 242757 W Pipe Support pair 80mm 5111081 FLUE GROUP B P Vertical Flue Kits K Vertical Flue Terminal 242802 L Pitched Ro...

Page 25: ...te 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 blanking plate to the boiler top panel Discard the plate 2 Fix both the air and flue adaptors with their gaskets onto the boiler top panel Secure with screws For Vertical Flues For Twin Flues Air Duct Adaptor Flue Duct Adaptor Gasket Gasket ...

Page 26: ...nd secure to the roof structure with the clamp supplied IMPORTANT If the boiler is not fitted immediately after the flue system temporary precautions must be taken to prevent rain entry into the room of installation Any precautionary measures must be removed prior to commissioning the boiler 8 7 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 270mm 105 8 and 800mm ...

Page 27: ...h the 70 110 concentric and 70Ø exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length of the concentric flue is 100mm when measured from the edge of the boiler flue elbow There is a further 45mm engagement into the elbow IMPORTANT The maximum equivalent length of concentric flue is 4 metres Additional elbows may be fi...

Page 28: ...mple 1 Not Permissible If for instance a concentric length of 3 25 metres was required and the 70Ø exhaust needed to be 10 metres the graph shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths OK Where both lengths have been determined they can be applied to the graph to check that the installation is permissib...

Page 29: ...support the concentric assembly and any extensions and make good inside and outside Secure the flue trim to the wall 9 The 70Ø exhaust can now be fitted to the spigot at the terminal end 10 If it is necessary to shorten the 70Ø exhaust or any of the extensions the excess material must be cut from the plain end of the pipe 11 Determine the position of the 70Ø exhaust and mark on the wall a suitable...

Page 30: ...t 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 93 elbow to allow the flue to be installed as shown in Fig H 18 When the plume outlet is positioned under a balcony or other projection Figs I J it must protrude at least 200mm it is not necessary to extend it further than this 200mm Min Fig H Fig I Fig J ...

Page 31: ...see table Fig 20 for wall thicknesses and flue diameters 6 Drill and plug the wall as previously marked Secure the wall plate Fig 22 7 Ensuring the wall plate is level both horizontally and vertically drill and plug at least 5 securing positions at the top and bottom through the wall plate Utilising the slots available ensure the wall plate is square and secure to the wall Fig 22 8 Additionally dr...

Page 32: ... Preparing The Boiler 1 Remove the outer carton and packaging 2 Lift the outercase upwards and remove 3 Remove the internal packaging Fig 22a Break Off Upper Lower Pipe Run Options Internal Polystyrene Packaging Piece Fig 23 Lower Door Panel Outercase ...

Page 33: ...he front connection is the flow pipe and the rear threaded connection is the return 2 It is essential that the flow and return pipes are connected to the boiler correctly The flow connection incorporates the boiler thermostats and a flow switch 3 The boiler connections will accept 22mm fittings 4 If the installation requires that the system pipework originates from the bottom of the boiler then th...

Page 34: ...ickness 181 3 Take the flue and mark off X from the terminal end as indicated in the diagram Fig 27 Check your dimensions The flue tubes are fixed together Cut through both tubes whilst resting the flue on the semi circular packing pieces Deburr both tube ends 4 For side exit measure the distance from the edge of the wall plate to the inner face of the wall Fig 26 and to this dimension add the wal...

Page 35: ...connection on top of the boiler Secure with the four screws supplied in the kit 11 Make good between the wall and air duct outside the building ensuring the 1 5 drop between the terminal and elbow 12 The flue trim should be fitted once the installation is complete and the flue secure Fig 30 Apply a suitable mastic to the inside of the trim and press against the wall finish making sure the brickwor...

Page 36: ...the support bracket This will prevent damage to the cable 4 Lay the cable through the cable clamp to gauge the length of cable required when it is connected to the 4 way terminal block 5 Connect the S L N and wires to the 4 way terminal block Fig 33 and refit the cable clamp Fig 31 6 Check the electrical installation for earth continuity short circuits resistance to earth correct polarity and fuse...

Page 37: ...een g y Green Yellow op Opaque y Yellow Gas Valve g op Spark Electrode g y bk bk bk bk r w w Flame Detection Electrode Condensate Trap Flow Overheat Thermostat Fan Overheat Thermostat g y r b r r Flow Thermistor 325Vdc DC Fan CH Flow Switch gy gy w g br PCB Earths not shown to aid clarity of diagram g y b y L N Optional Pump Feed br g y br b op op ...

Page 38: ... op Opaque y Yellow 11 2 Illustrated Wiring Diagram GasValve Fan CondensateTrap CH Flow Switch Flow Thermistor Spark Electrode Flame Detection Electrode Main PCB N L r r gy gy r b br g w Flow Overheat Thermostat Fan Overheat Thermostat bk bk bk r bk w w op g y Layout of PCB Pins Optional Pump Feed g y br y g y b br b y b br br ...

Page 39: ...with the inhibitor and attach to the inside of the boiler case Detail of system treatment should be added for future reference 6 Turn the gas supply on and purge according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 7 Remove the top RH securing screw and hinge down the PCB housing to gain access to the gas service cock see Fig 32 Turn the gas service cock anticlockwise to the ON ...

Page 40: ... the property working Measure the Gas Rate 4 With any other appliances pilot lights turned OFF the gas rate can be measured It should be as shown in Section 4 0 Technical Data 5 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the boiler and installation These details will be required in the event of any warranty...

Page 41: ...mplete a Declaration of Conformity to indicate compliance to I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist 6 Instruct the user in the operation of the boiler controls Hand over the User s Operating Installation and Servicing Instructions giving advice on the necessity of regular servicing 7 Demonstrate to the ...

Page 42: ...n for Installation Maintenance of Gas Fired Boilers not exceeding 70kW advises that The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers ...

Page 43: ... the Outercase Section 13 0 WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate at supply before access 7 Release the four 1 4 turn screws securing the air box door panel and remove the door Fig 39 8 Disconnect the leads from the centre and right hand terminals earth and flame sensing probe Fig 40 Reconnect in reverse order 9 Undo the four screws securing the combustion box door and remov...

Page 44: ...tion box base and withdraw the base j Lower the central insulation panel and check condition Fig 44 Replace the lower insulation pad if necessary k Ensure the heat exchanger fins are clear of any obstruction l Check condition of all seals Important Pay particular attention to the condition of the combustion box door seals m Reassemble in reverse order and check for leaks 12 Check the CO CO2 ratio ...

Page 45: ... before access 3 Isolate the water circuit and drain the system as necessary A drain point is located on the heat exchanger manifold at the right hand side of the boiler Fig 45 to enable the heat exchanger to be drained 4 Place a tube on the drain point to drain water away from electrics Turn anticlockwise to open Fig 45 NOTE When reassembling always fit new O rings ensuring their correct location...

Page 46: ...ission the boiler and check the inhibitor concentration see Section 6 2 and 12 1 15 4 PCB Figs 48 49 WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate at supply before access 1 Remove the plastic button cover Refit them onto the new PCB Fig 48 1 Remove the top right hand securing screw and hinge down the PCB housing and disconnect the electrical connections noting their positions 2 Lift...

Page 47: ... WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate at supply before access 1 Loosen the screw holding the injector pipe into the venturi 2 Remove the electrical connections to the fan and protection sensor on the fan 3 Remove the wing nuts securing the fan to the base of the combustion box 4 Lower the fan and remove 5 If changing the fan remove the screws securing the venturi and fan pr...

Page 48: ...r and gasket to the new valve 10 Fit the new gas valve and reassemble in reverse order NOTE Check for gas tightness after replacing gas valve 11 Check the CO CO2 ratio and CO2 level at the flue sampling point Fig 41a is as quoted in Section 4 0 Technical Data 12 If the ratio or level is greater than that quoted telephone the Technical Enquiries for further advice IMPORTANT No adjustment of the gas...

Page 49: ...it the new burner and reassemble in reverse order 15 11 Heat Exchanger 1 Drain the boiler see section 15 1 paragraph 2 3 2 Remove all components in the base of the airbox 3 Undo the screws on the support bracket Remove the screws securing the flow switch and return connections and remove the connections Fig 57 4 Remove the screws securing the heat exchanger manifold and remove the manifold Fig 58 ...

Page 50: ...anger and remove the lower insulation pad 6 Fit the new insulation pad and reassemble in reverse order 15 13 Heat Exchanger Upper Insulation Pad Fig 60 1 Remove all components in the base of the airbox 2 Remove the burner see section 15 10 3 Remove the heat exchanger see section 15 11 4 Remove the four bolts securing the combustion box base 5 Remove the combustion box base 6 Pull the central insul...

Page 51: ...058 Flow Temperature Thermistor Red 240670 B E06 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 5111714 I Electrodes Kit 5132097 J Burner Assy 5107430 K E06 097 Heat Exchanger Assy 242497 A B C E F G H I J K D ...

Page 52: ...ts replace LV wiring harness PCB Fault Replace PCB PCB Fault Replace PCB PCB Fault Replace PCB YES YES YES YES YES YES YES YES YES YES YES YES Go to Electrical Supply section of the fault finding instructions ON Go to Dry Fire section of the fault finding instructions Go to Overheat Lockout section of the fault finding instructions NOTE The fan is supplied with 325 Vdc Fan Fault Finding should onl...

Page 53: ...Systems Controls and System Wiring 240V at B Check wiring from terminal block to PCB Check for shorts on pump fan gas valve Replace if shorted replace fuse YES NO Replace PCB YES YES NO NO ELECTRICAL SUPPLY 240V at A PCB fuse OK B Fuse A N L Lights Off Off Off ON Optional Pump Live ...

Page 54: ...off on After 5 sec is there 240V at E Pump or Pump Wiring fault Is there a blockage in the system NO YES YES E Optional Pump Live N L F N L Turn mains off unplug 7 way connector to PCB Is there continuity between F and G Wiring from terminal block to PCB faulty NO YES Replace PCB Wires from inline connector to PCB faulty Remove flow switch from boiler Is there a physical blockage to the paddle wit...

Page 55: ...e as necessary YES YES NO NO YES Remove Gas Valve check inlet filter for blockage Otherwise incorrect gas supply to boiler Is there at least 18mbar dynamic at gas valve inlet Lead from PCB to Gas Valve faulty Is spark gap between 3 and 4mm Replace spark or flame detection probe and gaskets Is wiring from PCB to spark probe flame detection probe OK NO YES NO NO YES YES NO NO I Remove the larger or ...

Page 56: ...bustion chamber door seal trim seal NO YES NO YES Reconnect stat Disconnect fan stat When fan temp 60 C is there continuity across stat Reconnect stat Disconnect the larger of the 6 way PCB connectors Is there continuity across M Disconnect thermistor red sensor on flow pipe Is resistance between 0 5kè 20kè Is combustion chamber door seal damaged or not in place Replace PCB YES Replace thermistor ...

Page 57: ...Wire Entry end S W Fan Connection PCB Connection Fan Connection PCB Connection NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after the boiler has been electrically isolated Lights Flash Flash On ON THERMISTOR Replace thermistor Wiring from PCB to thermistor faulty YES NO NO YES Replace PCB Unplug thermistor Is thermistor resistance between 0 5kè 20kè Plug in th...

Page 58: ...em cleaner was used Gas Rate Burner Operating Pressure if applicable Central Heating Flow Temperature Central Heating Return Temperature Gas Rate Burner Operating Pressure at maximum rate Cold Water Inlet Temperature Hot Water has been checked at all outlets If required by the manufacturer record the following The heating and hot water system complies with the appropriate Building Regulations The ...

Page 59: ...Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments...

Page 60: ... 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 available on request 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 ...

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