Potterton Gold 4 kW User guide

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ELECTRIC BOILERS - 4, 6, 9, 11 & 12kW MODELS
RADIATOR & UNDERFLOOR VERSIONS
INSTALLATION AND SERVICING INSTRUCTIONS
PACK CONTENTS
The POTTERTON GOLD electric boiler
Guarantee registration card
Fitting & user instructions
IMPORTANT: PLEASE READ AND UNDERSTAND THESE INSTRUCTIONS
BEFORE COMMENCING INSTALLATION. PLEASE LEAVE THIS MANUAL
WITH THE CUSTOMER FOR FUTURE REFERENCE.

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THANK YOU FOR PURCHASING THIS POTTERTON GOLD ELECTRIC BOILER. IT HAS BEEN DEVELOPED
TO PROVIDE YOU WITH MANY YEARS OF TROUBLE-FREE SERVICE WHEN INSTALLED CORRECTLY
PLEASE READ AND UNDERSTAND THESE INSTRUCTION PRIOR TO INSTALLING YOUR POTTERTON GOLD
ELECTRIC BOILER. THIS POTTERTON GOLD ELECTRIC BOILER MUST BE INSTALLED, COMMISSIONED
AND MAINTAINED BY A COMPETENT PERSON ONLY. FOLLOWING INSTALLATION AND COMMISSIONING
THE OPERATION OF THE BOILER SHOULD BE EXPLAINED TO THE USER AND THESE INSTRUCTIONS LEFT
WITH THEM FOR FUTURE REFERENCE.
THIS APPLIANCE IS NOT INTENDED FOR USE BY PERSONS (INCLUDING CHILDREN) WITH REDUCED
PHYSICAL, SENSORY OR MENTAL CAPABILITIES, OR LACK OF EXPERIENCE AND KNOWLEDGE, UNLESS
THEY HAVE BEEN GIVEN SUPERVISION OR INSTRUCTION CONCERNING USE OF THE APPLIANCE BY A
PERSON RESPONSIBLE FOR THEIR SAFETY.
INTRODUCTION
FIGURE ONE: MAIN COMPONENTS OF POTTERTON GOLD ELECTRIC FLOW BOILER
OUTLET
RED IDENT
ELECTRICAL CABLE
ENTRY POINTS
EARTH CLAMP
TERMINAL BLOCK
MAIN PCB
BOILER ELEMENT
INSULATION
TEMPERATURE SWITCH
INLET
FRONT COVER (TOP)
WARNING LABEL
INSULATION SHEET
FLYING LEAD
CONTROL PANEL
FRONT COVER (BOTTOM)
RATING LABEL
SERIAL NUMBER

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The POTTERTON GOLD electric boiler is designed to heat re-circulated water used in wet central
heating systems. The water is heated when it is passed over electric immersion elements, which are
contained in a chamber. The temperature of the water is monitored and controlled by a modulation
technique switching on the immersion elements. The switching of the elements is carried out by
solid-state technology contained in the control section of the boiler. The operation of the boiler can
be controlled by standard programmers, room thermostats, etc. The pump should be connected to
the boiler control, which provides the run-on facility.
DESCRIPTION
Output Temperature Control Range: (Radiator) 650C to 800C.
(Underfloor) 300C to 600C
Operating voltage 200V - 245V 50Hz
Pump supply fuse (internal) T 2A 240V - 20x5mm.
‘RUN’ control input signal requires 200V - 245V 50Hz
‘RUN’ control input signal draws less than 0.25A. 10mA typical.
Optical isolation Between the control signals
and the boiler supply.
Over temperature trips 95 and 1000C
Water content 1.3 litres
Product code Boiler type 220V / Btu 240V / Btu Size
94022008 Rad 4kW 3.5kW / 11,900Btu 4kW / 13,600Btu 1050 x 90 x 90mm
94022108 U/floor 4kW 3.5kW / 11,900Btu 4kW / 13,600Btu 1050 x 90 x 90mm
94022004 Rad 6kW 5kW / 17,000Btu 6kW / 20,400Btu 1050 x 90 x 90mm
94022104 U/floor 6kW 5kW / 17,000Btu 6kW / 20,400Btu 1050 x 90 x 90mm
94022005 Rad 9kW 7.5kW / 25,600Btu 9kW / 30,700Btu 1050 x 90 x 90mm
94022105 U/floor 9kW 7.5kW / 25,600Btu 9kW / 30,700Btu 1050 x 90 x 90mm
94022006 Rad 11kW 9kW / 30,700Btu 11kW / 37,500Btu 1050 x 90 x 90mm
94022106 U/floor 11kW 9kW / 30,700Btu 11kW / 37,500Btu 1050 x 90 x 90mm
94022007 Rad 12kW 10kW / 34,000Btu 12kW / 40,900Btu 1050 x 90 x 90mm
94022107 U/floor 12kW 10kW / 34,000Btu 12kW / 40,900Btu 1050 x 90 x 90mm
Electric boiler for wet central heating systems.•
Domestic hot water is available from a cylinder.•
Can be used in a sealed or open vented system installations.•
No flue or fuel tank required.•
Quiet in operation.•
Operates from standard mains voltage programmers, room thermostats, etc.•
Pump run-on facility.•
Solid-state technology enables zero volt switching.•
Soft start and soft modulation.•
Front panel operation indicators.•
User adjustment of the operating temperature on the front panel.•
Self check every time it operates.•
Optical isolation to enable connection of more boilers on single or three phase supplies.•
Electrical tails terminations inside the boiler.•
Safety trip for no water or no flow situations.•
FEATURES
TECHNICAL SPECIFICATION

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Care must be taken when handling and connecting the boiler not to damage or stress it in any way.
Prior to installation the boiler must be stored in a dry, safe place.
The boiler must be mounted in an UPRIGHT position. The boiler must be fixed to a wall before
connecting pipework. When choosing the position for the boiler, ensure sufficient clearances to
house the unit and for servicing. 50mm minimum clearance each side of the boiler is required. A
drain valve at the base of the boiler is strongly recommended. It must be sited in a dry, ventilated
position, frost free and not subjected to extremes of temperature.
Note: Before connecting the pipework, ensure the rubber seal at the top of the boiler is firmly in place;
check it has not become loose in transit. The warranty will be invalid if water leaks into the boiler.
INSTALLATION - GENERAL
TOP HAUT ALTO OB EN
WARNING
Before obtaining acce ss to term inals all supply
circuitsm ust be di sconnected
Donot so lder directly onto flow and r eturn pipe work
Thegua rantee will be withdrawn if this product is
Notinsta lled ina ccorda nce with the installation
instructions
FIGURE TWO: DIMENSIONS
BACK VIEW
FRONT VIEW
SIDE VIEW
ENTRY PORTS
SUPPLY AND
CONTROL ON
BOTH SIDES
20mm 25.4mm
FLOW PIPEWORK
RED IDENT
RETURN PIPEWORK
5mm SECURING
HOLE
900mm FIXING CENTRES
30mm
1050mm
20mm
30mm
100mm
90mm

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The installation must be carried out in accordance with the relevant requirements of:
The appropriate Building Regulations, either The Building Regulations, The Building Regulations
(Scotland) or Building Regulations (Northern Ireland)
The Water Fittings Regulations or Water Byelaws in Scotland.
IT IS THE INSTALLER’S RESPONSIBILITY TO ENSURE THAT THE INSTALLATION DOES NOT CONTRAVENE
THE REQUIREMENTS OF THE WATER SUPPLY REGULATIONS, BUILDING REGULATIONS OR LOCAL
AUTHORITY REGULATIONS.
The boiler must be installed by a qualified, competent tradesman who is aware of and will comply with
all relevant standards that are applicable: e.g. Building Regulations, the Local Authority Regulations,
the Water Supply Regulations and undertaking the relevant British Standards. The system must be
flushed in accordance with BS 7593 and in accordance with the supplied instructions and drawings
to ensure proper operation.
The boilers contain a very small amount of water, and so require a sufficient flow rate of water to
ensure proper operation. The 4kW and 6kW product requires a minimum flow of 6 litres/minute,
and the 9kW, 11kW and 12kW require a minimum flow of 12 litres/minute. Insufficient flow of water
through the boiler will cause nuisance trip outs. The maximum temperature differential between
input and output of the boiler must not exceed 140C. If the temperature across the boiler exceeds
this then the flow rate is too low and will potentially damage the boiler. Set the flow rate to give 5 -
100C across the boiler on full heat.
The output FLOW pipe at the TOP of the boiler is identified RED. The input RETURN pipe is located
at the BOTTOM. Ensure that the direction of flow is correct through the boiler after installation. Set
the pump on maximum flow rate.
Pipework connections on all models are 22mm.
Use standard size pipework. DO NOT SOLDER DIRECTLY ONTO THE BOILER TAILS. Push-on or
compression fittings are suitable for connecting directly onto the boiler tails. Fit a 22mm elbow to the
top of the boiler and after 100 – 150mm of horizontal pipework fit an automatic air vent, or connect
the expansion pipework on open vented systems to provide a route for air to vent. DO NOT FIT THE
AAV DIRECTLY ABOVE THE BOILER.
The electric boiler is suitable for operation in sealed or open vented systems. It is also suitable for
schemes such as heating only, Y plan, S plan, zone heating, under floor heating, micro-bore via a
manifold, etc. If you are unsure about your application regarding suitability of the boiler, please do
not hesitate to contact your local supplier or Potterton Gold directly.
The cost of installation can be reduced if the electric boiler is used for heating only. Use a direct
type cylinder with immersion elements and a time clock for the domestic hot water, then connect the
electric boiler directly to the heating circuit and control it by a programmable room thermostat. If the
radiator circuit has a continuously open route for the water flow, then a bypass is not required. The
boiler sizing is for heating only in this case and does not have to be increased to allow for domestic
hot water as well.
Ensure there is always an open route for the water to flow in any installation, to meet the required
minimum flow rate of the boilers and to allow for the pump over run. If an open route through the
heating circuit can not be guaranteed, then a bypass, fitted with an automatic bypass valve, must be
fitted which meets the required minimum flow rates for the boiler.
The bypass must have a minimum of either 2 metres of 22mm continuous pipework, or be routed
through a radiator with minimum dimensions of 600 x 600mm. Automatic pressure opening valves
must be used with the bypass circuit, ensure they are installed correctly as per the manufacturer’s
instructions. Gate valves are not suitable. DO NOT FIT A VALVE BETWEEN THE BOILER AND THE SAFETY
PRESSURE RELIEF VALVE OR EXPANSION RELIEF SYSTEM.
INSTALLATION - PLUMBING

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The boilers are suitable for operating pressures up to 3 bar. Normal sealed systems operate at 1 to 1.5
bar. Ensure a safety pressure relief valve is fitted to all sealed systems. With open vented installations,
ensure there is a sufficient head of water for the pump to supply the full flow through the boiler of
at least 1½ metres between the bottom of the feed & expansion tank and the top of the boiler.
NOTE: TO COMPLY WITH BUILDING REGULATIONS, PART L (PART J IN SCOTLAND), WHEN THE ELECTRIC
BOILER IS USED FOR CENTRAL HEATING PURPOSES, A ROOM THERMOSTAT MUST BE FITTED TO
CONTROL THE BOILER (SEE PAGE 15).
Do not fit thermostatic radiator valves to the room with the control thermostat, other rooms may be
fitted with thermostatic radiator valves.
DO NOT OPERATE UNDER THERMOSTATIC RADIATOR VALVES ONLY.
Use standard pumps, controls, room thermostat, valves, etc. The main electrical power (high current)
must be routed directly to the boiler via an MCB and RCD, not through the controls. Only a control
signal to the boiler comes from the programmer. The switching of the high power current is done
inside the boiler.
For installations with more than one boiler, mount the boilers side-by-side with a minimum of 50mm
gap between each boiler, output flow tails at the top and the returns at the bottom. ‘Tee’ in the
flows together, increasing in pipe size at each boiler to ensure full flow to each boiler. E.g. for 3 x
12kW boilers, first boiler use a 22mm elbow to the second boiler. Second boiler tee 22mm in from
first boiler, 22mm branch to second boiler, 28mm to third boiler. Third boiler tee 28mm in from
second boiler, 22mm branch to third boiler, 35mm away to heating circuit. Repeat for the return
connections. Single pump in the 35mm flow line, ensure sufficient flow for all 3 boilers, i.e. (for 3
x 12kW boilers requires 3 x 12 l/m = 36 litres/minute minimum). Do not reduce pipework before
‘teeing’. See figure four on page 8.
When filling the system check for leaks. THE WARRANTY WILL BE INVALIDATED IF WATER LEAKS INTO
THE BOILER. ENSURE ALL JOINTS ABOVE THE BOILER ARE SOUND.
After installation the system must first be flushed out in accordance with BS 7593:1992 before
adding the inhibitor. Fernox “Superfloc”, or BetzDearborn Setinel X300 or X400 are ideal flushing
agents for new and existing systems. After flushing the correct amount of inhibitor must be added
before use. Fernox “Superconcentrate”, or MB-1, or BetzDearborn Sentinel X100 can be used for most
water areas, however we recommend you should check with your local water authority to ensure
suitability. Check the inhibitor concentration after installation and periodically thereafter to ensure
correct protection.
FAILURE TO FLUSH PROPERLY OR INADEQUATE INHIBITOR IN THE SYSTEM WILL INVALIDATE THE
WARRANTY.

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FIGURE THREE: BASIC PLUMBING LAYOUT
AUTOMATIC AIR VENT EXPANSION / SAFETY
RELIEF SYSTEM
SERVICE VALVE
PUMP
ISOLATING VALVE
150mm MINIMUM
2 METRES MINIMUM
ELECTRIC BOILER
AUTOMATIC
PRESSURE
BYPASS VALVE
FLOW
RETURN
DRAIN VALVE
ALTERNATIVE BY-PASS ARRANGEMENT
USING THE BATHROOM RADIATOR FITTED
WITH TWO LOCKSHIELD VALVES
OPEN VENTED SYSTEMS MUST
HAVE A MINIMUM HEAD OF
1.5 METRES AND MAXIMUM
HEAD OF 30 METRES

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A typical plumbing schematic connecting 3 x 12kW boilers together.
NOTE:
The increase in pipework sizing to ensure proper flow through the boilers.•
Ensure there are no restrictions in the heating circuit such as thermostatic radiator valves etc.•
The expansion vessel has not been shown on this schematic.•
For 2 x 12kW boilers, 28mm pipework flow and return is required.•
A bypass must be fitted. Preference should be made for a 600 x 600 radiator.•
FIGURE FOUR: THREE BOILER PLUMBING SCHEMATIC
AUTOMATIC AIR VENT EXPANSION / SAFETY
RELIEF SYSTEM
SERVICE
VALVE
PUMP
ELECTRIC BOILER
FLOW
DRAIN VALVE
ELECTRIC BOILER
ELECTRIC BOILER
35mm PIPE
FLOW
36 LITRE/
MIN
28mm PIPE
FLOW
24 LITRE/
MIN
22mm PIPE
FLOW
12 LITRE/
MIN
35mm PIPE
FLOW
36 LITRE/
MIN
28mm PIPE
FLOW
24 LITRE/
MIN
22mm PIPE
FLOW
12 LITRE/
MIN
RELAY
SYSTEM
94970058
RETURN

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ALL WIRING MUST BE CARRIED OUT IN ACCORDANCE WITH CURRENT IEE WIRING REGULATIONS.
The POTTERTON GOLD boiler must be installed by a qualified competent tradesman in accordance
with supplied instructions and drawings to ensure correct operation.
Check the main incoming supply to the property to ensure there is sufficient current and voltage
for the size of the boiler or boilers to be installed. Remember to also take account of the supply
requirements for the rest of the property. Ensure the correct cable size is used to feed the boiler
(refer to IEE wiring regulations).
A double pole RCD with a trip level sensitivity of 30mA and capable of breaking the full load current
to BS EN 61008:1994, must be used.
In order to provide a means of isolation, the boiler must be connected to the supply through a double
pole linked switch with a minimum contact gap of 3mm in all poles. The RCD is suitable for this
requirement if it is mounted in close proximity to the boiler.
A correctly rated MCB must be used in the supply, see Technical Specifications (page 3). An additional
3A supply is required for the controls etc. NOTE, a blank must be fitted between each MCB to provide
ventilation, check with the MCB manufacturer/supplier.
NOTE: The high current mains supply MUST NOT be routed through the programmer, controls etc.
Follow the wiring diagrams. Use a standard programmer, room thermostat, etc. The high current
switching is carried out inside the boiler, only standard switched live (low current) control signals
are supplied by the programmer etc.
Electrical Connections
Access can be gained to the electrical connections by removing the top front panel.
CONN 5: MAIN POWER. Main power-supply cables. Connect the power cables from the power1.
“supply” (CONN 5) terminals on the PCB assembly in the boiler directly to the isolation switch, live,
neutral and earth. Use the correct rated cable. Do not connect the power through the programmer,
thermostats etc. The main power PCB terminals in the boiler are suitable for cables up to 10mm2.
NOTE: THESE CONNECTIONS MUST BE TIGHT. LOOSE CONNECTIONS WILL CAUSE BURNING AT
CONN 5 CONNECTOR, THIS IS NOT COVERED BY THE WARRANTY.
CONN 1 pins 2 & 3: CONTROL SIGNAL. Connect switched live to ‘R’ and neutral to ‘N’ on the2.
control terminal block in the boiler to the switched live and neutral from the programmer control
circuit. A neutral must be connected, as this control signal is optically isolated from the main
supply in the boiler and will not run without a neutral. Do not connect any wires to the terminal
marked N/C.
CONN 1 pins 4, 5 & 6: PUMP CONNECTIONS. The supply to the pump must be connected to the3.
‘PUMP’ terminal on the control terminal block in the boiler. This supply is fused in the boiler at
2A.
Cable access is made from either the right or left hand side via the x3 knockouts provided (x14.
25mm for power and x2 20mm for pump and thermostat cables). Having decided which side to
route the cables, remove x3 knockouts only (This can be achieved with a small tap from a ball
nose hammer, then twisting the knockout untill it is removed. Note: Take care not to damage the
casing, ensure the metal discs are retrieved and no sharp edges are present. The cables should
be installed using a cable compression gland (not supplied).
INSTALLATION - ELECTRICAL REQUIREMENTS
x3 KNOCKOUTS
LEFT HAND SIDE
X3 KNOCKOUTS
RIGHT HAND SIDE
FIGURE FIVE: CASE KNOCKOUTS
FIGURE SIX: TWISTING KNOCKOUT

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Connections for 2 or more boilers.
1 CONN 5: Main power-supply cables. Connect each boiler to its supply live, neutral, and earth,
as described above. The supplies to each boiler can be on different phases if using a 3-phase
supply.
2 CONN 1 pins 2 & 3: Control signal. Join all the boiler ‘R’ terminals on the control terminal
block together, and then connect them to the switched live control signal to the programmer
control circuit. Connect all the boiler ‘N’ terminals on the control terminal block together and
then to neutral on the programmer control circuit.
3 CONN 1: Pump connections. The pump must be connected through a relay assembly to
ensure that the pump always operates if any one boiler is running. See page 26. Relay
box 94970057 is required for a two boiler system and 94970058 is required for a 3 boiler
system.
Check the main electrical power connections are tight. Support the back of the PCB behind the power
terminals when tightening the main power terminals. Loose connections can cause burning at the
connectors and will invalidate the warranty.
The control RUN signal is optically isolated from the main boiler supply to enable different phases to
be used between boilers. The control signal required to operate the boiler is 220V - 240V at a very
low current, typically 10mA.
WARNING: THIS APPLIANCE MUST BE EARTHED.
All exposed pipework must be earthed in accordance with IEE Regulations.
After installation, preliminary electrical checks i.e. short circuit, earth continuity, resistance to earth
and check for correct polarity etc. must be carried out.
Before connecting the electrical supply, ensure the system is full of water and set to the correct
pressure (sealed systems), check for leaks. It is essential that all the air is purged from the system.
Only then can the supply be switched on.
On completion of the work the installation must be tested to IEE Regulations and an NICEIC Inspection
and Completion Certificate must be issued.
Please take note of the installation information. If in doubt please contact your local supplier or
Potterton Gold.
FIGURE SEVEN: BOILER INTERNAL SCHEMATIC
N E L
CONN5
N R E N L
CONN1
CONTROL
ELEMENT