Baxi Potterton WH65, WH46 User Manual

WALL-MOUNTED CONDENSING BOILERS

WH 46
WH 65

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

0085

GB

IE

Dear Customer,

We are sure your new boiler will comply with all your requirements.

Do not dispose of this booklet as it contains the information, which will help you to run your
boiler correctly and efciently.

Do not leave any parts of the packaging (plastic bags, polystyrene, etc.) within children’s reach as they are a
potential source of danger.

POTTERTON GOLD HIGH OUTPUT boilers bear the CE mark in compliance with the
basic requirements as laid down in the following Directives:

- Gas Directive 2009/142/CE

- Performance Directive 92/42/CEE

- Electromagnetic Compatibility Directive 2004/108/CE

- Low Voltage Directive 2006/95/CE

CONTENTS

INSTRUCTIONS PERTAINING TO THE USER

1. 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

INSTRUCTIONS PERTAINING TO THE INSTALLER

8. General information 11

9. Instructions prior to installation 11

10. Boiler installation 12

11. Boiler size 13

12. Installation of ue and air ducts 13

13. Hydraulic system 16

14. Connecting the mains supply 20

15. Gas valve adjustment 27

16. Setting the boiler parameters 29

17. Control and operation devices 30

18. Positioning of the ignition and ame sensing electrode 31

19. Check of combustion parameters 31

20. Activating the chimney-sweep function 32

21. Annual service 32

22. Boiler schematic 33

23. Illustrated wiring diagram 34

24. Technical data 35

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926.772.1 - GB/IEINSTRUCTIONS PERTAINING TO THE USER

1. INSTRUCTIONS PRIOR TO INSTALLATION

This boiler is designed to heat water at a lower than boiling temperature at atmospheric pressure. The boiler
must be connected to a central heating system and/or to a domestic hot water supply system in compliance
with its performances and output power.
The boiler must be installed by a Qualied Service Engineer ensuring that the following operations are carried
out:

a) Careful checking that the boiler is t for operation with the type of gas available. For more details see the

notice on the packaging and the label on the appliance itself.

b) Careful checking that the ue terminal draft is appropriate; that the terminal is not obstructed and that no

other appliance exhaust gases are expelled through the same ue duct, unless the ue is especially desi­gned to collect the exhaust gas coming from more than one appliance, in conformity with the standards
and regulations in force.

c) Careful checking that, in case the ue has been connected to pre-existing ue ducts, thorough cleaning

has been carried out in that residual combustion products may come off during operation of the boiler and
obstruct the ue duct.

d) To ensure 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 must be used in response to current regulations.

2. Heating circuit

2.1. New system
Before proceeding with installation of the boiler, the system must be cleaned and ushed 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 the maker’s directions. Finally the system must be dosed with a suitable inhibitor
at 1% system volume.

2.2. Existing system
Before proceeding with installation of the boiler, the system must be cleaned and ushed out to remove

sludge and contaminants, using suitable proprietary products as described in section 2.1.

To avoid damaging metal, plastic and rubber parts, use only neutral cleaners, i.e. non-acid and non-

alkaline such as SENTINEL X100 and FERNOX heating circuit protective.

Remember that the presence of foreign matter in the heating system can adversely affect the operation

of the boiler (e.g. overheating, noisy operation, or failure of the heat exchanger may occur).

Failure to observe the above will render the warranty null and void.

2. INSTRUCTIONS PRIOR TO COMMISSIONING

Initial lighting of the boiler must be carried out by a qualied service engineer. Ensure the following operations
are carried out:
a) Compliance of boiler parameters with (electricity, water, gas) supply systems settings.
b) Compliance of installation with the standards and regulations in force.
c) Appropriate connection to the power supply and earthing of the appliance.
Failure to observe the above will render the warranty null and void.
Prior to commissioning remove the protective plastic coating from the unit. Do not use any tools or abrasive
detergents as you may damage the painted surfaces.

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926.772.1 - GB/IEINSTRUCTIONS PERTAINING TO THE USER

3. COMMISSIONING OF THE BOILER

To correctly light the burner proceed as follows:

1) Provide power supply to the boiler;

2) Open the gas cock;

3) Follow the directions given below regarding the adjustments to be made at the boiler control panel.

Figure 1

020503_1100

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 to a hot water system.

KEYS DISPLAY SYMBOLS

Hot water on/off key

Central heating water temperature setting key

Hot water temperature setting key

Operation in hot water mode

Operation in central heating mode

Operation in automatic mode

Operation in manual mode at the maximum

Reset key

Program access and scroll keys

Program access and scroll key

Parameter setting key (decrease value)

Parameter setting key (increase value)

Data display reset key

temperature set

Operation in manual mode at minimum tem­perature

Standby (off)

Outdoor temperature

Flame present (on)

Resettable alarm warning

Central heating mode setting key

MAIN display

SECONDARY display

926.772.1 - GB/IEINSTRUCTIONS PERTAINING TO THE USER

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3.1 DESCRIPTION OF KEYS

(2) This key can be pressed to set the central heating water output temperature as described in point

3-3.

(3) This key can be pressed to set the hot water temperature as described in point 3-4.

(10) Central heating mode operating key

The key can be pressed to activate four boiler central heating operating modes; these modes are

identied by a black cursor line underneath the relative symbol on the display, and are as follows:

Dash

“Automatic mode”

active

Figure 2

020503_0800

a) Automatic operation. Operation of the boiler is controlled by the timed program as described in point

3-5.1 “Daily timed program for operation of the central heating system”;

b) Manual operation at the maximum temperature set. The boiler comes into operation regardless of

the timed program set. The operating temperature is that set using the key (point 3-3: “Setting
the maximum central heating temperature”);

c) Manual operation at minimum temperature. The operating temperature is that set in point 3-6:

“setting the minimum central heating temperature”.

The manual transition from positions a) and b) to position c) involves shut-down of the burner and

disconnection of the pump after the post-circulation delay interval (the factory setting for this parameter
is 3 minutes).

d) standby. The boiler does not work in central heating mode, although the frost protection function is

still enabled.

(1) Hot water on/off key: Press this key to activate or inhibit this function, which is identied 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 least two seconds) to restart the boiler.

(9) Data key. This key can be pressed repeatedly to display the following information:

- Temperature (°C) of the hot water ( );

- outdoor temperature (°C) ( ); only provided with the outdoor temperature sensor probe
connected.

Press either of the keys to return to the main menu.

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926.772.1 - GB/IEINSTRUCTIONS PERTAINING TO THE USER

3.2 SETTING THE TIME

a) Press either of the keys to access the programming function;
the display will show the letter P followed by a number (program line);

Figure 3

b) Press the keys until the display shows P1, referring to the time to be set;

c) Press the keys to set the time; on the display, the letter P will start to ash;

d) Press the key to save and exit the programming function;

020503_0700

3.3 SETTING THE MAXIMUM CENTRAL HEATING TEMPERATURE

- Press the key (2-gure 1) to set the central heating water temperature;

- Press the keys to set the temperature required;

- Press either of the keys (1 or 10 - gure 1) to save and return to the main menu.

N.B – With the outdoor sensor connected, the key (2 - gure 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.

3.4 SETTING THE MAXIMUM HOT WATER TEMPERATURE

- Press the key (3-gure 1) to set the maximum hot water temperature;

- Press the keys to set the temperature required;

- Press either of the keys (1 or 10 - gure 1) to save and return to the main menu.

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926.772.1 - GB/IEINSTRUCTIONS PERTAINING TO THE USER

3.5 SETTING THE DAILY PROGRAM FOR OPERATION IN CENTRAL HEATING AND DOMESTIC HOT WATER MODES

3.5.1 Setting the daily times for central heating mode operation

- Press either of the keys to access the programming function;

a) Press these keys until the display shows P11, referring to the program start time;

b) Press the keys to set the time;

- Press the key; the display will show P12, referring to the program end time;

- Repeat the operations described in points a and b until the third and last cycle is reached (program line

P16);

- Press the key to save and exit from the programming function.

3.5.2 Setting the daily times for domestic hot water mode operation

- As supplied 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 specically 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 CENTRAL HEATING TEMPERATURE

- Press either of the keys to access the programming function;

- Press these keys until the display shows p5, referring to the temperature to be set;

- Press the keys to set the temperature required.

This operating mode is enabled when minimum temperature central heating mode “ ” is activated or when
the daily central heating program does not require heat.

N.B – With the outdoor sensor connected, parameter P5 can be used to set the minimum room tempe­rature in the premises to be heated (night setback).

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926.772.1 - GB/IEINSTRUCTIONS PERTAINING TO THE USER

3.7 TABLE FOR USER-SETTABLE PARAMETERS

Parameter

N.

P1 Time of day setting ———- 0…23:59

P5 Minimum central heating temperature setting (°C) 25 25..80

P11 Start of rst daily period of automatic central heating 6:00 00:00…24:00

P12 End of rst daily period of automatic central heating 22:00 00:00…24:00

P13 Start of second daily period of automatic central heating 0:00 00:00…24:00

P14 End of second daily period of automatic central heating 0:00 00:00…24:00

P15 Start of third daily period of automatic heating 0:00 00:00…24:00

P16 End of third daily period of automatic central heating 0:00 00:00…24:00

P31 Start of rst daily period of hot water production (*) 0:00 00:00…24:00

P32 End of rst daily period of hot water production (*) 24:00 00:00…24:00

P33 Start of second daily period of hot water production (*) 0:00 00:00…24:00

P34 End of second daily period of hot water production (*) 0:00 00:00…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

Parameter description

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. Conrm by pressing either of the keys

Factory

setting

0 0...1

Range

Note: Parameters from P31 to P36 can be displayed only if the domestic hot water program has been enabled
as described in chapter 17 for the attention of the installer (parameter H91).

3.8 FAULT WARNINGS AND RESETTING THE BOILER

If a fault occurs, a ashing warning code appears
on the display.
The fault warnings appear on the main display (gure

1 a) together with the symbol (Figure 4).
To reset, press the reset button for at least two

seconds.

Fault warnings appear on the secondary display
(gure 1 b) alternating with the time, both of them
ashing (gure 4.1). It is not possible to reset mal­function warnings which appear on the secondary
display as the cause of the alarm has rst to be
removed.

020503_0500

Figure 4

0509_0201

8

Figure 4.1

926.772.1 - GB/IEINSTRUCTIONS PERTAINING TO THE USER

3.9 FAULT WARNINGS TABLE

Fault code Fault description action required

E10 outdoor temperature probe sensor failure call the authorised service centre.

E20 ntc output sensor failure call the authorised service centre

E40 NTC return heating probe faulty call the authorised service centre

E50 domestic hot water ntc sensor failure call the authorised service centre

E110

E111 Delivery temperature higher than 95°C If this fault persists, call the authorised service centre

E128

E129 Minimum fan speed limit is hurt Call an authorised service centre.

E132 oor thermostat tripped call the authorised service centre

E133 no gas

E151 boiler circuit board error

E153 the reset key has been pressed inappropriately press the key again (about 2 seconds)

E154

E160 fan speed threshold not reached call the authorised service centre.

E164 no hydraulic pressure switch enabling signal

Safety or fumes thermostat or heating return
temperature probe tripped

Loss of ame during operation (the ionization current
has fallen below the limit)

No circulation or reverse flow call the authorised service centre

press the reset key (for about 2 seconds: if this device is triggered
repeatedly, call the authorised service centre)

Call an authorised service centre.

press the reset key (for about 2 seconds); if the fault persists,
call the authorised service centre)

Press the reset button if the display presents the ( ) symbol,
otherwise switch off the boiler at the mains and switch it on again
after 10 seconds. If the fault persists, call an authorised service
centre. Check the position of the ignition electrodes (chapter 17).

check that the system is at the rated pressure. (refer to the
section on lling the system). if the fault persists, call the
authorised service centre.

All the faults are displayed in order of importance; if several faults occur simultaneously, the rst to be displa­yed is the one with highest priority. After the cause of the rst fault has been removed, the second one will
be displayed, and so on.
If any given fault occurs frequently, contact the authorised Service Centre.

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926.772.1 - GB/IEINSTRUCTIONS PERTAINING TO THE USER

4. FILLING THE BOILER

Important: Regularly check that the pressure displayed by the pressure gauge is between 1 to 4 bar, with the
boiler not operating.
In case the pressure is lower open the boiler lling tap.
We recommend you open the tap very slowly in order to let off the air.
In case pressure drops occur frequently have the boiler checked by a Qualied Service Engineer.

5. TURNING OFF THE BOILER

To shut down the boiler switch off the electrical supply to the appliance.

6. PROLONGED STANDSTILL OF THE SYSTEM. FROST PROTECTION

We recommend you avoid draining the whole system as raw water makeup will lead to harmful limestone
deposits inside the boiler and on the heating elements.
In case the boiler is not operated during wintertime and is therefore exposed to danger of frost we suggest you
add some specic-purpose anti-freeze to the water contained in the system (e.g.: propylene glycole coupled
with corrosion and scaling inhibitors).
The electronic management of the boilers includes a ‘frost protection’ function which operates the burner to
reach a heating ow temperature of 30° C when the system heating ow 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.

7. SERVICING INSTRUCTIONS AND GAS CHANGE

To maintain efcient and safe operation of your boiler have it checked by a Qualied Service Engineer at the
end of every heating season. Careful servicing will ensure economical operation of the system.
Do not clean the outer casing of the appliance with abrasive, aggressive and/or easily ammable cleaners
(i.e.: gasoline, alcohol, and so on). Always isolate the electrical supply to the appliance before cleaning it (see
section 5 Turning off the boiler).

These boilers are produced for natural gas and can be converted to work with LPG (G 31).
Any gas change must be effected by a Qualified Service Engineer.

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926.772.1 - GB/IEINSTRUCTIONS PERTAINING TO THE USER

8. GENERAL INFORMATION

The following remarks and instructions are addressed to Service Engineers to help them carry out a faultless
installation. Instructions regarding lighting and operation of the boiler are contained in the ‘Instructions per­taining to the user’ section.
Note that installation, maintenance and operation of the gas appliances must be performed exclusively by
qualied personnel in compliance with current standards.
Please note the following:
* This boiler can be connected to any type of double- or single feeding pipe convector plates, radiators,

thermoconvectors. Design the system sections as usual though taking into account the available output /
pump head performances.

* Do not leave any packaging components (plastic bags, polystyrene, etc.) within children’s reach as they are

a potential source of danger.

* Initial lighting of the boiler must be effected by a Qualied Service Engineer.

Failure to observe the above will render the warranty null and void.

9. INSTRUCTIONS PRIOR TO INSTALLATION

This boiler is designed to heat water at a lower than boiling temperature at atmospheric pressure. The boiler
must be connected to a central heating system and, on models with this option, to a domestic hot water supply
system in compliance with its performances and output criteria.

IMPORTANT! The gas boiler is supplied without the following components which must be provided exclusively
by qualied personnel:

• Expansion vessel;

• Pressure relief valve;

• Circulating pump;

• Boiler lling tap.

Before connecting the boiler ensure the following operations have been completed:

a) Check that the boiler is t for operation with the type of gas available. For more details see the notice on

the packaging and the label on the appliance itself.

b) Check that the ue terminal draft is appropriate; that the terminal is not obstructed and that no other applian-

ce exhaust gases are expelled through the same ue duct, unless the ue is especially designed to collect
the exhaust gas coming from more than one appliance, in conformity with the standards and regulations in
force.

c) Check that, in case the ue has been connected to pre-existing ue ducts, thorough cleaning has been

carried out in that residual combustion products may be created during operation of the boiler and obstruct
the ue duct.

To ensure 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 system must be cleaned and ushed out thoroughly

to eliminate residual thread-cutting swarf, solder and solvents if any, using suitable proprietary products.

INSTRUCTIONS PERTAINING TO THE INSTALLER 926.772.1 - GB/IE

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