Potterton Gold 4 kW Installation And Servicing Instructions
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Potterton Gold 4 kW Installation And Servicing Instructions

Electric boilers, radiator & underfloor versions
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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.
1

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  • Page 1: Installation And Servicing Instructions

    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...
  • Page 2 INTRODUCTION 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.

  • Page 3: Technical Specification

    DESCRIPTION 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.

  • Page 4: Installation - General

    INSTALLATION - GENERAL 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.

  • Page 5: Installation - Plumbing

    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.
  • Page 6 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...
  • Page 7 EXPANSION / SAFETY AUTOMATIC AIR VENT RELIEF SYSTEM 150mm MINIMUM OPEN VENTED SYSTEMS MUST HAVE A MINIMUM HEAD OF 1.5 METRES AND MAXIMUM HEAD OF 30 METRES PUMP ISOLATING VALVE FLOW AUTOMATIC PRESSURE BYPASS VALVE RETURN SERVICE VALVE DRAIN VALVE ALTERNATIVE BY-PASS ARRANGEMENT USING THE BATHROOM RADIATOR FITTED WITH TWO LOCKSHIELD VALVES...
  • Page 8 AUTOMATIC AIR VENT EXPANSION / SAFETY RELIEF SYSTEM 22mm PIPE 28mm PIPE 35mm PIPE FLOW FLOW FLOW 12 LITRE/ 24 LITRE/ 36 LITRE/ PUMP FLOW RELAY SYSTEM 94970058 SERVICE VALVE 35mm PIPE 28mm PIPE 22mm PIPE DRAIN VALVE FLOW FLOW FLOW RETURN 36 LITRE/...

  • Page 9: Installation - Electrical Requirements

    INSTALLATION - ELECTRICAL REQUIREMENTS 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.
  • Page 10 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. CONN5 CONN1...
  • Page 11 MAINS SUPPLY BOILER SUPPLY CONSUMER UNIT MCB MCB DOUBLE POLE RCD OR DOUBLE POLE ISOLATION 3A FUSED SPUR OR MCB LOCAL TO BOILER DOUBLE POLE ISOLATION SWITCH TO CONTROLS OR DOUBLE POLE PROGRAMMER / ETC DEMAND SIGNAL FROM CONTROLS/ PROGRAMMER ETC (SEE TYPICAL WIRING DIAGRAMS) HEAT RESISTANT...
  • Page 12 MAINS SUPPLY CABLE Refer to BS7671 for cable sizing PUMP SUPPLY CABLE 0.5mm - 1mm BOILER CONTROL CABLE 0.5mm - 1mm CASE EARTH NO CONNECTION CONTROL PUMP SUPPORT BACK NC N R E N L OF PCB WHEN TIGHTENING SCREWS NC N R E N L SUPPLY CONTROL...
  • Page 13 CYLINDER STAT ROOM STAT 2 PORT VALVES 1 C 2 2 1 3 BLUE GRN/YLW BROWN GREY ORANGE BLUE GRN/YLW BROWN FROM 3A GREY ORANGE FUSED SPUR OR MCB BOILER TIME CONTROLLER FIGURE TEN: TYPICAL S PLAN WIRING DIAGRAM...
  • Page 14 MID POSITION CYLINDER VALVE ROOM STAT STAT 2 1 3 C 1 2 BLUE G/YELLOW WHITE GREY ORANGE FROM 3A FUSED SPUR OR MCB BOILER TIME CONTROLLER FIGURE ELEVEN: TYPICAL Y PLAN WIRING DIAGRAM PROGRAMMABLE ROOM THERMOSTAT A B C FROM 3A FUSED SPUR OR MCB...
  • Page 15 INSTALLATION - REVISED BUILDING REGULATIONS Heating Controls To Comply With The Revised Building Regulations (Part L For England. Part J for Scotland). New Dwelling 1. The installation must be a fully pumped system. 2. Independent temperature and time controls for both heating and domestic hot water. 3.
  • Page 16 COMMISSIONING The boiler controls are fully automatic, making the operation very simple. Only after the system has been flushed through and then filled with water, inhibitor and set to the correct pressure (sealed systems), can the electrical supply be switched on. Check 1.
  • Page 17 Check the full system operates correctly. If at any time the temperature difference between the boiler return and flow is greater that 14 C, then there is a flow restriction problem, and must be rectified immediately. Set pump speed to give 5-10 C differential between return and flow on the boiler when operating at maximum power output.
  • Page 18 MAIN POWER ON IS TEMP SWITCH OPEN CALL LED RED I.E. FAULTY OR ALARM LED FLASHING BOILER OVER TEMP CONTINUE CHECK FOR ALL AS LONG AS BOILER IS POWERED RUN TO ON PUMP ON AND PRE-HEAT ON THEN WAIT FOR 1 - 1.5 MINUTES DO BOTH ALARM LED FLASHING THERMISTOR BEADS...

  • Page 19: Operation & Indicators

    OPERATION & INDICATORS The SUPPLY indicator (green) will remain illuminated all the time the supply is present to the boiler. The CALL indicator will illuminate (green) on demand from the programmer and thermostats or (red) for an alarm overheat condition. It will flash (green) for 2 to 3 minutes during which it carries out self-tests before allowing the boiler to produce heat.
  • Page 20 REPLACING THE MAIN POWER PCB Note: Before any maintenance is carried out on the system, ensure that the electrical supply has been disconnected first. Care must be taken as the water may be scalding hot and at high pressure. Maintenance on the boiler can only be carried out by a qualified and competent tradesman in accordance with supplied instructions.

  • Page 21: Fault Finding

    This is due to a leakage current from some manufacturers 3 port valves. The capacitor required is 0.47 micro-farads suitable for 275 volts AC (X2 style). These capacitors are available from Potterton Gold 95612708. ALARM RESET There are 3 steps to re-set a tripped condition: - Switch “...
  • Page 22 THE BOILER IS NOT GO TO SUPPLY LED OFF THE SUPPLY LED OPERATING FAULT FINDING SECTION ILLUMINATED PLEASE CHECK THE FOLLOWING BEFORE GOING THROUGH THE FAULT FINDING CHART: CHECK INSTALLATION IS IS THE CORRECT GO TO ALARM ALARM LED FAULT FINDING SECTION ILLUMINATED ALL ISOLATING VALVES ARE OPEN...
  • Page 23 SUPPLY LED OFF IS THE CHECK 240V IS SUPPLIED MAIN SUPPLY TO THE MAIN POWER TERMINAL AVAILABLE CONN5 CHECK FOR SHORT CIRCUITS IS THERE ON WIRING TO THE PUMP. 230V ON TVR 1 IF OK REPLACE FS1 FUSE. MAIN PCB T 2A 240V 20 x 5mm IS THERE 8V DC ON...
  • Page 24 ALARM TRIPS DURING THERE IS NO WATER IN THE SYSTEM. SELF CHECKING BUT NOT SWITCH OFF IMMEDIATELY. INSTANTLY CHECK AND FILL BEFORE RESTARTING. FIGURE TWENTY: ALARM TWO ALARM TRIPS AFTER A FEW MINUTES OF OPERATION CHECK FOR A RESTRICTION IN THE FLOW. IS THE PUMP CHECK THE BYPASS, CHECK THE SERVICE RUNNING...
  • Page 25 CALL LED NOT FLASHING IS THE 240V CHECK AND SET THE PROGRAMMER DEMAND AVAILABLE AND THERMOSTATS ON IS THERE 230V CHECK THE WIRING TO BETWEEN R AND N THE BOILER CONTROL IS NEUTRAL NEUTRAL MUST BE CONNECTED CONNECTED TO TO N ON THE CONTROL CONNECTOR N CONTROL CHANGE THE CONTROL PCB FIGURE TWENTY THREE: CALL LED NOT FLASHING...
  • Page 26 PUMP - RELAY CONTROL FOR POTTERTON GOLD ELECTRIC BOILERS 2 or 3 boilers on single phase 240V or three phase 415V supply Isolation relays must be used as shown in figure twenty five below for 2 or more boilers to operate the pump.

  • Page 27: Limitations On Electrical Supply

    A suitable relay unit is available from POTTERTON GOLD. Part number 94970056. This relay unit is also suitable for other applications where there is a high load demand to be shared with the boiler.

  • Page 28: Environmental Information

    Brooks House, Coventry Road, Warwick, CV34 4LL Tel: 0844 809 4954 The policy of POTTERTON GOLD is one of continuous product development and, as such, we reserve the right to change specifications and guarantee terms and conditions without notice. 36006089_issue_03...

This manual is also suitable for:

Gold 6 kwGold 9 kwGold 11 kwGold 12 kw

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