Potterton Gold 24 HE Installation and maintenance instructions

Installation & Service Instructions Gold Combi HE
Range
This is a Wall Mounted Powered Flue Condensing Combination Boiler Gas Fired Central Heating Unit.
The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency) Regulations 1993 No3083” and is
deemed to meet the requirements of Directive 92/42/EEC on the energy efficiency requirements for new hot water
boilers fired with liquid or gaseous fuels:-
Type test for purpose of Regulation 5 certified by:
Notified Body 0085.
Product/Production certified by:
Notified Body 0085.
For use in GB/IE only.
These instructions include the Benchmark Commissioning Checklist and should be left with the User for safe keeping.

Publication No. 5116282
2
Natural Gas
Potterton Gold 24 HE
G.C.No47 590 05
Potterton Gold 28 HE
G.C.No47 590 06
Potterton Gold 33 HE
G.C.No47 590 19
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 Persons Self Certification Scheme as an
option to notifying the Local Authority directly. Similar
arrangements will follow for Scotland and will apply in
Northern Ireland from 1 January 2006.
CORGI operate a Self Certification Scheme for gas
heating appliances.
These arrangements represent a change from the
situation whereby compliance with Building Regulations
was accepted as being demonstrated by completion of
the Benchmark Logbook (which was then left on site
with the customer).
With the introduction of Self Certification Schemes, the
Benchmark Logbook is being withdrawn. However, a
similar document in the form of a commissioning
checklist and service interval record is incorporated at
the back of these instructions.
Potterton is a member of the Benchmark initiative and
fully supports the aims of the programme. Its aim is to
improve the standards of installation and commissioning
of central heating systems in the UK and to encourage
the regular servicing of all central heating systems to
ensure safety and efficiency.
Building Regulations require that installations should
comply with manufacturer's instructions. It is therefore
important that the commissioning checklist is completed
by the installer. The relevant section of Building
Regulations only relates to dwellings. Therefore the
checklist only applies if the appliance is being installed
in a dwelling or some related structure.
The flowchart opposite gives guidance for installers on
the process necessary to ensure compliance with
Building Regulations.

3
INSTALLER NOTIFICATION GUIDELINES
Publication No. 5116282
Choose Building
Regulations Notification
Route
Contact your relevant Local
Authority Building Control
(LABC) who will arrange
an inspection or contact
a government approved
inspector
LABC will record the data
and will issue a
certificate of compliance
CORGI will record the data and
will send a certificate of
compliance to the property
You must ensure that the
notification number issued by
CORGI is writen onto the
Benchmark Checklist
Scheme Members only
Call CORGI on: 0870 88 88 777
or log onto:
www.corgi-notify.com
within 10 days
If you notify via CORGI Scheme,
CORGI will then notify the
relevant Local Authority
Building Control Scheme
on member's behalf
Complete the
Benchmark Checklist
Install and Commission this
appliance to manufacturer's
instructions
Competent Person's
Self Certification Scheme Building Control

LEGISLATION
4Publication No. 5116282
Codes of Practice - refer to the most recent
version
IMPORTANT - Installation, Commissioning, Service & Repair
This appliance must be installed in accordance with the manufacturer’s
instructions and the regulations in force. Read the instructions fully before
installing or using the appliance.
In GB, this must be carried out by a competent person as stated in the Gas
Safety (Installation & Use) Regulations.
Definition of competence: A person who works for a CORGI registered
company and holding current certificates in the relevant ACS modules, is
deemed competent.
In IE, this must be carried out by a competent person as stated in I.S. 813
“Domestic Gas Installations”.
Lifting - This product should be lifted and handled by two people. Stooping
should be avoided and protective equipment worn where necessary. Carrying
& lifting equipment should be used as required, e.g. when installing in a loft
space.
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.
All CORGI registered installers carry a CORGI identification card and have a
registration number. You can check your installer is registered by telephoning
0870 4012300 or writing to:-
1 Elmwood,
Chineham Business Park,
Crockford Lane,
Basingstoke. RG24 8WG
or check online at www.corgi-gas-safety.com
Potterton declare that no substances harmful to
health are contained in the appliance or used
during appliance manufacture.
The appliance is suitable only for installation in GB
and IE and should be installed in accordance with
the rules in force, and only used in a suitably
ventilated location.
In GB, the installation must be carried out by a CORGI
Registered Installer. It must be carried out in accordance
with the relevant requirements of the:
•Gas Safety (Installation & Use) Regulations.
•The appropriate Building Regulations either The
Building Regulations, The Building Regulations
(Scotland), Building Regulations (Northern Ireland).
•The Water Fittings Regulations or Water Byelaws in
Scotland.
•The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference
should be made to the relevant British Standard Code of
Practice.
In IE, the installation must be carried out by a competent
Person and installed in accordance with the current
edition of I.S. 813 ‘Domestic Gas Installations’, the
current Building Regulations and reference should be
made to the current ETCI rules for electrical installation.
All systems must be thoroughly flushed and
treated with inhibitor (see section 6.2).
In GB the following Codes of Practice apply:
Standard Scope
BS 6891 Gas Installation.
BS 5546 Installation of hot water supplies for
domestic purposes.
BS 5449 Forced circulation hot water systems.
BS 6798 Installation of gas fired hot water boilers.
BS 5440 Part 1 Flues.
BS 5440 Part 2 Ventilation.
BS 7074 Expansion vessels and ancillary equipment
for sealed water systems.
BS 7593 Treatment of water in domestic hot water
central heating systems.
In IE the following Codes of Practice apply:
Standard Scope
I.S. 813 Domestic Gas Installations.
The following standards give valuable additional information;
BS 5546 Installation of hot water supplies for
domestic purposes.
BS 5449 Forced circulation hot water systems.
BS 7074 Expansion vessels and ancillary equipment
for sealed water systems.
BS 7593 Treatment of water in domestic hot water
central heating systems.

5
CONTENTS
1.0 Introduction 6
2.0 General Layout 7
3.0 Appliance Operation 8
4.0 Technical Data 9
5.0 Dimensions and Fixings 12
6.0 System Details 13
7.0 Site Requirements 16
8.0 Installation 22
9.0 Commissioning 28
10.0 Completion 31
11.0 Servicing 32
12.0 Changing Components 34
13.0 Combustion Check 43
14.0 Electrical 44
15.0 Short Parts List 45
16.0 Fault Finding 46
17.0 Notes 52
Benchmark Checklist 54
Section Page
Publication No. 5116282

1.0 INTRODUCTION
6
1.1 Description
1. The Potterton Gold Combi HE is a fully automatic
gas fired wall mounted condensing combination boiler.
It is room sealed and fan assisted, and will serve
central heating and mains fed domestic hot water.
2. The boiler is set to give a maximum output of :-
24 models - 24 kW DHW
25.9 kW CH (Condensing)
28 models - 28 kW DHW
25.9 kW CH (Condensing)
33 models - 33 kW DHW
30.3 kW CH (Condensing)
3. It is designed for use on Natural Gas (G20).
4. The boiler is suitable for use only on fully pumped
sealed heating systems. Priority is given to domestic
hot water.
5. The boiler is supplied with a filling loop and integral
timer.
6. The boiler data badge gives details of the model,
serial number and Gas Council number and is situated
on the control box. It is visible when the case front
panel is removed (Fig. 1).
7. The boiler is intended to be installed in residential /
commercial / light industrial E.M.C. environments on a
governed meter supply only.
8. The boiler must be installed with one of the purpose
designed flues such as the standard horizontal flue kit,
part no. 5111073.
9. All systems must be thoroughly flushed and
treated with inhibitor (see section 6.2).
1.2 Optional Extras
Various flue extensions, bends, vertical flue kits, etc.
are available as optional extras. These are detailed in
a separate publication.
NOTE: All illustrations show the Gold Combi 24 HE
unless otherwise stated.
Data Badge
Fig. 1
Control Box
Case Front Panel
Publication No. 5116282

7
2.0 GENERAL LAYOUT
2.1 Layout
1. Expansion Vessel
2. Automatic Air Vent
3. DHW Plate Heat Exchanger
4. Circulation Pump
5. Drain Off Point
6. Pressure Relief Valve
7. Integral Timer Position
8. Central Heating System Pressure Gauge
9. PCB
10. Control Box
11. 3-Way Valve Assembly
12. Condensate Trap
13. Flame Sensing Electrode
14. Spark Electrode
15. Primary Heat Exchanger
16. Fan Assembly
17. On/Off/Reset Selector Switch
18. Central Heating Temperature Control
19. Hot Water Temperature Control
20. Venturi
21. Air/Gas Collector
22. Combustion Box Cover & Burner
23. Igniter
24. Burner On Light
25. Central Heating Mode Light
26. Domestic Hot Water Mode Light
27. Display
1
17 18 19 87
2
1
0
4
3
bar
Reset
1
2
3
4
5
PM
7
8
9
10
11
12
1
2
3
4
5
AM
7
8
9
10
11
12
GRASSLIN
0
22
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
20
21
23
24
25 26
27
Publication No. 5116282

3.0 APPLIANCE OPERATION
8
3.1 Central Heating Mode (Fig. 2)
1. With a demand for heating, the pump circulates
water through the primary circuit.
2. Once main burner ignites the fan speed controls the
gas rate to maintain the heating temperature
measured by the temperature sensor.
3. When the flow temperature exceeds the setting
temperature, a 3 minute delay occurs before the
burner relights automatically (anti-cycling). The pump
continues to run during this period.
4. When the demand is satisfied the burner is
extinguished and the pump continues to run for a
period of 3 minutes (Pump Overrun).
3.2 Domestic Hot Water Mode (Fig. 3)
1. Priority is given to the domestic hot water supply. A
demand at a tap or shower will override any central
heating requirement.
2. The flow of water will operate the Hall Effect Sensor
which requests the 3 way valve to change position.
This will allow the pump to circulate the primary water
through the DHW plate heat exchanger.
3. The burner will light automatically and the
temperature of the domestic hot water is controlled by
the temperature sensor.
4. When the domestic hot water demand ceases the
burner will extinguish and the diverter valve will
remain in the domestic hot water mode, unless there
is a demand for central heating.
IMPORTANT: When the selector switch is in the ‘0’
(Off) position the electrical supply to the boiler is
isolated. The boiler will not operate and the integral
timer will require resetting once the selector switch
is set to either Position (i) or Position (ii).
3.3 Frost Protection Mode
1. The frost protection mode is integral to the
appliance and functions only with the selector switch
(see Section 2.1) in the domestic hot water and
central heating position. If the system temperature
falls below 5°C then the boiler will fire on its minimum
setting until a flow temperature of 30°C is reached.
Further protection can be incorporated by using a
system frost thermostat.
3.4 Pump Protection
1. With the selector switch (see Section 2.1) in either
the central heating or central heating and domestic hot
water position, the pump will automatically operate for
1 minute in every 24 hours to prevent sticking.
1
2
4
5 6
7
8
9
10
11
1213141516
17
18
19
21
22
24
25
26
3
1 Primary Heat Exchanger
2 Burner
3 Ignition Electrode
4 Flame Sensing Electrode
5 Gas Valve
6Pump
7 Automatic Air Vent
8 Plate Heat Exchanger
9 Flow Sensor with Filter & Regulator
10 Pressure Relief Valve
11 Boiler Drain Point
12 Heating Return
13 Cold Water Inlet On/Off Valve and Filter
14 Gas Inlet
15 Domestic Hot Water Outlet
16 Heating Flow
17 Pressure Gauge
18 Water Pressure Sensor
19 Automatic By-Pass
20 Fan
21 Diverter Valve Assembly
22 Diverter Valve Motor
23 Domestic Hot Water Flow Temperature Sensor
24 Safety Thermostat
25 Central Heating Temperature Sensor
26 Expansion Vessel
Key
Central Heating Circuit
Domestic Hot Water Circuit
Fig. 3
1
2
4
5 6
7
8
9
10
11
1213141516
17
18
19
21
22
24
25
26
3
Fig. 2
23
23
20
20
Publication No. 5116282

9
4.0 TECHNICAL DATA
4.1 Gold Combi 24 HE
Flue Terminal Diameter 100mm
Dimensions Projection 125mm
Outercase Dimensions
Casing Height - 780mm
Overall Height Inc Flue
Elbow - 965mm
Casing Width - 450mm
Casing Depth - 345mm
Weights kg
Packaged Boiler Carton 56.5
Installation Lift Weight 45
Central Heating Primary Circuit
Pressures
bar
Safety Discharge 3
Max Operating 2.5
Min Operating 0.5
Recommended Operating Range 1-2
DHW Circuit bar
Pressures
Max Operating 8
Min Operating 0.15
Flow Rates l/min
DHW Flow Rate
@ 30o C Rise 11.43
DHW Flow Rate
@ 35o C Rise 9.8
Min Working
DHW Flow Rate 2
Pump
Available Head See graph below
Expansion Vessel - (For Central Heating
only. Integral with appliance)
bar
Min Pre-charge Pressure 0.5
litre
Max Capacity of
CH System 125
Primary Water Content
of Boiler (unpressurised) 2.5
Connections copper tails
Gas Supply - 22mm
Central Heating Flow - 22mm
Central Heating Return - 22mm
Cold Water Mains Inlet - 15mm
DHW Flow - 15mm
Pressure Relief Discharge - 15mm
Temperatures
C.H. Flow Temp (adjustable)
25°C to 80°C max (± 5°C)
D.H.W. Flow Temp (adjustable)
35°C to 60°C max (± 5°C)
dependent upon flow rate
NOxClass 5
0
200 400 600 800 1000 1200
0.5
1
1.5
2
2.5
3
3.5
4
Metre (wg)
Flow Rate (l/h)
Pump - Available Head
0
5
5.5
4.5
Clearances
Above Casing 200 mm Min
Below Casing 200 mm Min
Front 450 mm Min (For Servicing)
Front 5 mm Min (In Operation)
L.H. Side 5 mm Min
R.H. Side 5 mm Min (In Operation)
Heat Input CH (Net)
Max Min
kW 24.7 7
Heat Output CH (Non-Condensing)
Max Min
kW 24 6.8
Electrical Supply 230V~ 50Hz
(Appliance must be connected to an
earthed supply)
Power Consumption 155W
Electrical Protection IPX0D
Internal Fuse Rating
F2L
Appliance Category CAT I 2H
Inlet Pressure (Natural Gas - G20)
mbar 20
Injector (Natural Gas - G20)
7.5mm
Appliance Type C13 C33
Heat Output CH (Condensing)
Max Min
kW 25.9 7.4
Heat Input DHW (Net)
Max
kW 24.7
Heat Output DHW
Max
kW 24
Max Gas Rate (Natural Gas - G20)
(After 10 mins)
m3/h 2.61
This value is used in the UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data from
which it has been calculated have been certified by 0085.
SEDBUK Declaration For Gold 24 HE
The seasonal efficiency (SEDBUK) is 90.1%
Band A
Condensate Drain
To accept 21.5mm (3/4in) plastic waste pipe
Heat Input CH (Gross)
Max Min
kW 27.4 7.8
Heat Input DHW (Gross)
Max
kW 27.4
Publication No. 5116282
External Fuse Rating 3A

4.0 TECHNICAL DATA
10 Publication No. 5116282
4.2 Gold Combi 28 HE
Flue Terminal Diameter 100mm
Dimensions Projection 125mm
Outercase Dimensions
Casing Height - 780mm
Overall Height Inc Flue
Elbow - 965mm
Casing Width - 450mm
Casing Depth - 345mm
Weights kg
Packaged Boiler Carton 56.5
Installation Lift Weight 45
Central Heating Primary Circuit
Pressures
bar
Safety Discharge 3
Max Operating 2.5
Min Operating 0.5
Recommended Operating Range 1-2
DHW Circuit bar
Pressures
Max Operating 8
Min Operating 0.15
Flow Rates l/min
DHW Flow Rate
@ 30o C Rise 13.3
DHW Flow Rate
@ 35o C Rise 11.5
Min Working
DHW Flow Rate 2
Pump
Available Head See graph below
Expansion Vessel - (For Central Heating
only. Integral with appliance)
bar
Min Pre-charge Pressure 0.5
litre
Max Capacity of
CH System 125
Primary Water Content
of Boiler (unpressurised) 2.5
Connections copper tails
Gas Supply - 22mm
Central Heating Flow - 22mm
Central Heating Return - 22mm
Cold Water Mains Inlet - 15mm
DHW Flow - 15mm
Pressure Relief Discharge - 15mm
Temperatures
C.H. Flow Temp (adjustable)
25°C to 80°C max (± 5°C)
D.H.W. Flow Temp (adjustable)
35°C to 60°C max (± 5°C)
dependent upon flow rate
NOxClass 5
0
200 400 600 800 1000 1200
0.5
1
1.5
2
2.5
3
3.5
4
Metre (wg)
Flow Rate (l/h)
Pump - Available Head
0
5
5.5
4.5
Clearances
Above Casing 200 mm Min
Below Casing 200 mm Min
Front 450 mm Min (For Servicing)
Front 5 mm Min (In Operation)
L.H. Side 5 mm Min
R.H. Side 5 mm Min (In Operation)
Heat Input CH (Net)
Max Min
kW 24.7 9
Heat Output CH (Non-Condensing)
Max Min
kW 24 8.7
Electrical Supply 230V~ 50Hz
(Appliance must be connected to an
earthed supply)
Power Consumption 155W
Electrical Protection IPX0D
Internal Fuse Rating
F2L
Appliance Category CAT I 2H
Inlet Pressure (Natural Gas - G20)
mbar 20
Injector (Natural Gas - G20)
7.5mm
Appliance Type C13 C33
Heat Output CH (Condensing)
Max Min
kW 25.9 9.5
Heat Input DHW (Net)
Max
kW 28.9
Heat Output DHW
Max
kW 28
Max Gas Rate (Natural Gas - G20)
(After 10 mins)
m3/h 3.1
This value is used in the UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data from
which it has been calculated have been certified by 0085.
SEDBUK Declaration For Gold 24 HE
The seasonal efficiency (SEDBUK) is 90.1%
Band A
Condensate Drain
To accept 21.5mm (3/4in) plastic waste pipe
Heat Input CH (Gross)
Max Min
kW 27.4 10
Heat Input DHW (Gross)
Max
kW 32.1
External Fuse Rating 3A