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 efficiently.

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 flue 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 flame 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

INSTRUCTIONS PERTAINING TO THE USER	2	926.772.1 - GB/IE

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 Qualified Service Engineer ensuring that the following operations are carried out:

a)Careful checking that the boiler is fit 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 flue terminal draft is appropriate; that the terminal is not obstructed and that no other appliance exhaust gases are expelled through the same flue duct, unless the flue 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 flue has been connected to pre-existing flue ducts, thorough cleaning has been carried out in that residual combustion products may come off during operation of the boiler and obstruct the flue 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 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 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 flushed 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 nonalkaline 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 qualified 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.

INSTRUCTIONS PERTAINING TO THE USER	3	926.772.1 - GB/IE

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.

020503_1100

Figure 1

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

Hot water on/off key

Central heating water temperature setting key

Hot water temperature setting key

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

Central heating mode setting key

DISPLAY SYMBOLS

Operation in hot water mode

Operation in central heating mode

Operation in automatic mode

Operation in manual mode at the maximum temperature set

Operation in manual mode at minimum temperature

Standby (off)

Outdoor temperature

Flame present (on)

Resettable alarm warning

MAIN display

SECONDARY display

INSTRUCTIONS PERTAINING TO THE USER	4	926.772.1 - GB/IE

3.1DESCRIPTION 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 identified by a black cursor line underneath the relative symbol on the display, and are as follows:

0800_020503

Dash “Automatic mode” active

Figure 2

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 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 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.

INSTRUCTIONS PERTAINING TO THE USER	5	926.772.1 - GB/IE

	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);

020503_0700

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

3.3 SETTING THE MAXIMUM CENTRAL HEATING TEMPERATURE

- Press the key (2-figure 1) to set the central heating 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.

N.B – With the outdoor sensor connected, 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.

3.4 SETTING THE MAXIMUM HOT WATER 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.

INSTRUCTIONS PERTAINING TO THE USER	6	926.772.1 - GB/IE

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

3.5.1Setting 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.

3.5.2Setting 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 domestic 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.

3.6SETTING 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).

INSTRUCTIONS PERTAINING TO THE USER	7	926.772.1 - GB/IE

3.7 TABLE FOR USER-SETTABLE PARAMETERS

Parameter	Parameter description		Factory	Range
N.			setting
P1	Time of day setting		———-	0…23:59
P5	Minimum central heating temperature setting (°C)		25	25..80
P11	Start of first daily period of automatic central heating		6:00	00:00…24:00
P12	End of first 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 first daily period of hot water production (*)		0:00	00:00…24:00
P32	End of first 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
	Reset of daily central heating and domestic hot water production programs (factory
P45	settings). Press the - + keys together for about 3 seconds; the number 1 appears on the		0	0...1
	display. Confirm by pressing either of the	keys

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 flashing warning code appears on the display.

The fault warnings appear on the main display (figure 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 (figure 1 b) alternating with the time, both of them flashing (figure 4.1). It is not possible to reset malfunction warnings which appear on the secondary display as the cause of the alarm has first to be removed.

Figure 4

020503_0500

0509_0201

INSTRUCTIONS PERTAINING TO THE USER	8	926.772.1 - GB/IE

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	Safety or fumes thermostat or heating return	press the reset key (for about 2 seconds: if this device is triggered
		temperature probe tripped	repeatedly, call the authorised service centre)
	E111	Delivery temperature higher than 95°C	If this fault persists, call the authorised service centre
	E128	Loss of flame during operation (the ionization current	Call an authorised service centre.
		has fallen below the limit)
	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 persists,
			call the authorised service centre)
			Press the reset button if the display presents the ( ) symbol,
	E151	boiler circuit board error	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).
	E153	the reset key has been pressed inappropriately	press the key again (about 2 seconds)
	E154	No circulation or reverse flow	call the authorised service centre
	E160	fan speed threshold not reached	call the authorised service centre.
			check that the system is at the rated pressure. (refer to the
	E164	no hydraulic pressure switch enabling signal	section on filling 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 first to be displayed is the one with highest priority. After the cause of the first fault has been removed, the second one will be displayed, and so on.

If any given fault occurs frequently, contact the authorised Service Centre.

INSTRUCTIONS PERTAINING TO THE USER	9	926.772.1 - GB/IE

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 filling 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 Qualified 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 specific-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 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.

7. SERVICING INSTRUCTIONS AND GAS CHANGE

To maintain efficient and safe operation of your boiler have it checked by a Qualified 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 flammable 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.

INSTRUCTIONS PERTAINING TO THE USER	10	926.772.1 - GB/IE

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 qualified personnel in compliance with current standards.

Please note the following:

*This boiler can be connected to any type of doubleor 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 Qualified 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 qualified personnel:

•Expansion vessel;

•Pressure relief valve;

•Circulating pump;

•Boiler filling tap.

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

a)Check that the boiler is fit 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 flue terminal draft is appropriate; that the terminal is not obstructed and that no other appliance exhaust gases are expelled through the same flue duct, unless the flue 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 flue has been connected to pre-existing flue ducts, thorough cleaning has been carried out in that residual combustion products may be created during operation of the boiler and obstruct the flue 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 flushed out thoroughly to eliminate residual thread-cutting swarf, solder and solvents if any, using suitable proprietary products.

INSTRUCTIONS PERTAINING TO THE INSTALLER	11	926.772.1 - GB/IE