Baxi Potterton WH65 User Manual

WALL-MOUNTED CONDENSING BOILERS

WH 46

WH 65

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

0085

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 desi-

gned 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 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 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

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.

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

DISPLAY SYMBOLS

Operation in hot water mode

Operation in central heating mode

Operation in automatic mode

Central heating water temperature setting key

Hot water temperature setting key

Operation in manual mode at the maximum

temperature set

Reset key

Operation in manual mode at minimum tem-

perature

Program access and scroll keys

Standby (off)

Program access and scroll key

Outdoor temperature

Flame present (on)

Parameter setting key (decrease value)

Parameter setting key (increase value)

Data display reset key

Resettable alarm warning

Central heating mode setting key

MAIN display

SECONDARY display

INSTRUCTIONS PERTAINING TO THE USER

926.772.1 - GB/IE

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

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

Dash

“Automatic mode”

active

Figure 2

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”;

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

the maximum central heating temperature”);

key (point 3-3: “Setting

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).

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

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);

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;

key to save and exit the programming function;

d) Press the

3.3 SETTING THE MAXIMUM CENTRAL HEATING TEMPERATURE

- Press the

key (2-ﬁgure 1) to set the central heating water temperature;

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;

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

926.772.1 - GB/IE

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 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.

3.6 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 tempe-

rature in the premises to be heated (night setback).

INSTRUCTIONS PERTAINING TO THE USER

926.772.1 - GB/IE

3.7 TABLE FOR USER-SETTABLE PARAMETERS

Parameter

Factory

setting

Parameter description

Range

Time of day setting

———-

0…23:59

Minimum central heating temperature setting (°C)

Start of ﬁrst daily period of automatic central heating

End of ﬁrst daily period of automatic central heating

Start of second daily period of automatic central heating

End of second daily period of automatic central heating

Start of third daily period of automatic heating

End of third daily period of automatic central heating

Start of ﬁrst daily period of hot water production (*)

End of ﬁrst daily period of hot water production (*)

Start of second daily period of hot water production (*)

End of second daily period of hot water production (*)

Start of third daily period of hot water production (*)

End of third daily period of hot water production (*)

25..80

P11

P12

P13

P14

P15

P16

P31

P32

P33

P34

P35

P36

6:00

22:00

0:00

24:00

0:00

00:00…24:00

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

P45

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

seconds.

button for at least two

Figure 4

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 mal-

function warnings which appear on the secondary

display as the cause of the alarm has ﬁrst to be

removed.

Figure 4.1

INSTRUCTIONS PERTAINING TO THE USER

926.772.1 - GB/IE

3.9 FAULT WARNINGS TABLE

Fault code

E10

Fault description

action required

outdoor temperature probe sensor failure

ntc output sensor failure

call the authorised service centre.

call the authorised service centre

E20

E40

NTC return heating probe faulty

domestic hot water ntc sensor failure

E50

Safety or fumes thermostat or heating return

temperature probe tripped

press the reset key (for about 2 seconds: if this device is triggered

repeatedly, call the authorised service centre)

E110

E111

E128

Delivery temperature higher than 95°C

If this fault persists, call the authorised service centre

Loss of ﬂame during operation (the ionization current

has fallen below the limit)

Call an authorised service centre.

E129

E132

Minimum fan speed limit is hurt

ﬂoor thermostat tripped

Call an authorised service centre.

call the authorised service centre

press the reset key (for about 2 seconds); if the fault persists,

call the authorised service centre)

E133

no gas

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).

E151

boiler circuit board error

E153

E154

E160

the reset key has been pressed inappropriately

No circulation or reverse ﬂow

press the key again (about 2 seconds)

call the authorised service centre

call the authorised service centre.

fan speed threshold not reached

check that the system is at the rated pressure. (refer to the

section on ﬁlling the system). if the fault persists, call the

authorised service centre.

E164

no hydraulic pressure switch enabling signal

All the faults are displayed in order of importance; if several faults occur simultaneously, the ﬁrst to be displa-

yed 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

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

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 per-

taining 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 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 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 applian-

ce 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

926.772.1 - GB/IE

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. Please ensure to use this product

proceeding strictly in accordance with the manufacturers instructions. Finally ﬁll the system with the

correct strength of central heating inhibitor.

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 non-

alkaline such us SENTINEL X100 and FERNOX heating circuit protective. To use this product proceeding

strictly in accordance with the maker’s directions.

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

of the boiler (e.g. overheating and noisy operation of the heat exchanger). Dose with inhibitor.

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

10. BOILER INSTALLATION

Decide upon the boiler location, then tape the template on the wall.

Connect the pipework to the gas and water inlets prearranged on the template lower bar.

If you are either installing the boiler on a pre-existing system or replacing it, we suggest you also ﬁt strainers

on the system return pipework to the boiler to collect the deposits and scaling which may remain and be

circulated in the system after the initial ﬁlling.

When the boiler is ﬁxed on the template connect the ﬂue and air ducts (ﬁttings supplied by the manufacturer)

according to the instructions given in the following relevant sections.

Connect the condensate outlet to the siphon supplied with the boiler. Connect the siphon to a drain, making

sure there is a continuous slope. Horizontal sections must be avoided.

DRILL HOLES WITH A Ø12 BIT, FIT THE MASONRY

PLUGS AND THE SCREWS PROVIDED

N.B. INCLUDE CONDENSATE DRAIN POINT

BOILER WIDTH 600

MR: G 1” heating ﬂow

GAS: G 3/4” gas inlet to the boiler

RR: G 1” heating return

SC: condensation drain 22 mm

Figure 5

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

11. BOILER SIZE

Figure 6

12. INSTALLATION OF FLUE AND AIR DUCTS

We guarantee ease and ﬂexibility of installation for the boiler thanks to the ﬁttings and ﬁxtures supplied (de-

scribed below).

The boiler is especially designed for connection to an exhaust ﬂue / air ducting, with either concentric, vertical

or horizontal terminal.

Where exhaust and intake ﬂues not

supplied by POTTERTON GOLD HIGH

OUTPUT have been installed, these

must be certiﬁed for the type of use

and must have a maximum pressure

drop of 100 Pa for the complete ﬂue

installation.

C₃₃

C₁₃

0709_1001

Figure 7

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

HORIZONTAL CONCENTRIC FLUES

Number of Bends 90°

Boiler

Flue Size

WH46

WH65

Ø80/125

9 m

8 m

7 m

6 m

VERTICAL CONCENTRIC FLUES

Number of Bends 90°

Boiler

Flue Size

WH46

WH65

Ø80/125

9 m

8 m

7 m

6 m

CONVENTIONAL FLUE

Number of Bends 90°

Boiler

Flue Size

WH46

WH65

Ø80

59,5 m

59 m

58,5 m

58 m

Concentric ﬂue

This type of duct allows to emit exhaust gases and to draw combustion air from outside the building.

The 87° coaxial bend allows to connect the boiler to a ﬂue-air duct in any direction as it can rotate through

360°.

If the ﬂue outlet is placed outside, the ﬂue-air ducting must protrude at least 18mm out of the wall to allow

alluminium weathering tile to be ﬁtted and sealed to avoid water leakages. If the terminal is below 2m then a

terminal gaurd is required.

Ensure a minimum downward slope of 3° towards the boiler.

A 87° bend reduces the total ﬂue length by 1 metre.

A 45° bend reduces the total ﬂue length by 0.5 metre.

Concentric outlet

Figure 8

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

12.1 HORIZONTAL FLUE TERMINAL Ø 80/125 INSTALLATION OPTIONS

L = refer to table

12.2 VERTICAL FLUE TERMINAL Ø 80/125 mm INSTALLATION OPTIONS

This type of installation can be carried out both on a ﬂat or pitched roof by ﬁtting a terminal, an appropriate

weathering tile and sleeve, (supplementary ﬁttings supplied as options).

L = refer also the table

L max = 10 m

L max = 8 m

L max = 9 m

12.5 FAN RPM UPDATING DEPENDING ON FLUE LENGTH (e.g. ﬁgure 7)

To ensure the correct rated heat output to the maximum and minimum heat input, it is necessary to update

the speed (rpm) of the fan, it depends on the length of the ﬂue (par. 12), in accordance with the installation of

ﬂue and air pipes as indicated in the tables below. The factory-set value is referred to the minimum length of

ﬂue pipe (0÷4 m for concentric, 0÷20 m for twin). To carry such updating, changing the speed of the fan (rpm)

at the maximum and minimum heat input, refer to par. 16.

WH 65

WH 46

CONCENTRIC PIPE Ø 80/125

(C13-C33-C43)

CONCENTRIC PIPE Ø 80/125

(C13-C33-C43)

Parametres

H536-H613

Parametres

H612

Parametres

H536-H613

Parametres

H612

Pipes length (m)

Max heat output (rpm) Min heat output (rpm)

(*) 0 - 4

5 - 10

(*) 0 - 4

5 - 10

5500

5900

1900

2100

6000

6500

1850

2100

(*) Default setting parameters

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

13. HYDRAULIC DIAGRAM

Applications and Installation Details

13.1 HYDRAULIC SYSTEM 1

(Pumped heating circuits with remote control QAA73 or Room Thermostat, including hot-water tank, without

and with primary loop)

(*)

(*) optional extra

(*)

without low loss header

Figure 9a

(*)

(*) optional extra

(*)

with low loss header and primary loop

Figure 9b

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

•

TS: Tank Sensor (QAZ36)*

B3: Room Control Module (QAA73)*

B1: Room Thermostat

B9: Outdoor Temperature Sensor (QAC34)*

P1: Heating Pump

PDHW: Hot Water pump

PLP: Primary Pump (only for ﬁgure 9b)

(*) Available Optional Extra

•

Pumps (Not Supplied)

Isolating Valve (Not Supplied)

Installer Wiring --------------

Hot Water Cylinder (Not Supplied)

Low Loss Header (Not Supplied)

Non return valve (Not supplied)

Applications (pumps, sensor, remote control ...) have to be connected to terminal as follows (see also section 14):

WITH QAA73

WITH

REMOTE CONTROL

ROOM THERMOSTAT

APPLICATION

TERMINAL BOARD

M1: A – B

TERMINAL BOARD

M1: A – B

M3: 13 – 14

M3: 11 – 12

M2: 7 – 8

PRIMARY PUMP PLP (only for ﬁgure 9b)

DHW PUMP PDHW

M3: 13 – 14

M3: 11 – 12

M2: 7 – 8

HEATING PUMP P1

DHW SENSOR TS

REMOTE CONTROL QAA73

ROOM THERMOSTAT

M2: 1 – 2

M2: 3 – 4 OPEN

M2: 3 – 4

Parameter changes requires (see also section 16):

PCB

Description

PARAMETER

Setting Parameter

H552

H553

H615

H632

Hydraulic system

KonﬁgHKS

H552 = 2

H553 = 21

KonﬁgAusgang

Wanfo Q8

H615 = 9

H632 = 00001100

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

13.2 HYDRAULIC SYSTEM 2

(Pumped heating circuits with Room Thermostat and compensated circuit with remote control QAA73, inclu-

ding hot-water tank, with primary loop)

• TS:Tank Sensor (QAZ36)*

• B3: Room Control Module (QAA73)*

• B1: Room Thermostat

• B9: Temperature Sensor (QAC34)*

• Zone Controller (Clip-in AGU2.500)*

• FS: Flow Sensor (QAD36: supplied with AGU2.500)*

• P1: Heating Pump

• P DHW: Hot Water pump

• PLP: Primary Pump

• 3WV: 3-way Valve (power open / power close)

(*) Available Optional Extra

• Pumps (Not Supplied)

• Isolating Valve (Not Supplied)

• Installer Wiring --------------

• Hot Water Cylinder (Not Supplied)

• Low Loss Header (Not Supplied)

• Non Return Valve (Not supplied)

HEATING CIRCUIT

COSTANT TEMP.

HEATING CIRCUIT

VARIABLE TEMP.

AGU 2.500*

Figure 10

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

Applications (pumps, sensor, remote control ...) have to be connected to terminal as follows (see also section 14):

APPLICATION

TERMINAL BOARD

M1: A – B

PRIMARY PUMP PLP

DHW PUMP PDHW

M3: 13 – 14

HEATING PUMP P1

DHW SENSOR TS

M3: 11 – 12

M2: 7 – 8

REMOTE CONTROL QAA73 (LOW TEMPERATURE)

ROOM THERMOSTAT

HEATING PUMP P2

3 WAY VALVE

M2: 1 – 2

M2: 3 – 4

CLIP IN AGU 2.500

FLOW SENSOR

Parameter changes requires (see also section 16):

PCB

Description

PARAMETER

Setting Parameter

H552

H553

H615

H632

Hydraulic system

KonﬁgHKS

H552 = 50

H553 = 12

KonﬁgAusgang

Wanfo Q8

H615 = 9

H632 = 00001111

13.3 HEAT EXCHANGER PRESSURE DROP

Hydraulic Resistance and Water Flow Rates

Boiler

11°C ∆T

kPa

15°C ∆T

kPa

20°C ∆T

kPa

30°C ∆T

kPa

Lit/sec

0,98

Lit/sec

0,72

Lit/sec

0,54

Lit/sec

0,36

WH46

WH65

70,61

56,88

31,38

34,32

11,77

20,59

10,79

11,77

1,41

1,04

0,78

0,52

Minimum Water Flow Rates

Boiler

Lit/sec

0,28

WH46

WH65

0,35

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

14. CONNECTING THE MAINS SUPPLY

Electrical safety of the appliance is only guaranteed by correct earthing, in compliance with the applicable

standards and regulations.

Connect the boiler to a 230V earthed power supply by means of the three-pin cable supplied ensure that the

polarity is correct.

Use a double-pole switch isolator with a contact separation of at least 3mm in both poles.

In case you replace the power supply cable ﬁt a HAR H05 VV-F’ 3x0.75mm²cable with an 8mm diameter

maximum outer sheath.

The fuse, a fast-acting type rated 2A, is incorporated into the power supply terminals (remove the black fuse

holder to enable inspection and/or replacement).

IMPORTANT: Check that the overall current drawn by accessories connected to the appliance is less than 1

amp. If the value is greater, a relay must be wired between the boiler control circuit board and the accessories

drawing the higher current.

Terminal board M1

Terminal board M2

Cover

Figure 11

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

14.1 CONNECTING THE PUMPS

Turn the control box downward to access terminal boards M1 and M3 used for the electrical connections by

removing the protective covers (see ﬁgure 12).

Terminals M1 a – b: connection of the primary loop pump for the heating system (PLP)

Check the correct size and rating of the pump by referring to its hydraulic resistance table.

Terminals M3 11 – 12: connection for heating pump (P1)

Terminals M3 13 – 14: connection for hot water tank pump (PDHW)

The electrical speciﬁcations of the pump must be as follows:

230 V AC; 50 Hz; 1 A max; cos f > 0.8.

If the speciﬁcations of the installed pump are different, a relay must be wired between the boiler control circuit

board and the pump.

It is advisable not to adopt any electrical connection other than those described.

Connect earth to earth strip

Figure 12

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

14.2 CONNECTING THE HOT WATER TANK SENSOR

Remove the resistor from terminals 9-10 of terminal strip M2 (ﬁgure 13), and connect the hot water priority

NTC sensor, which is supplied as an accessory.

The sensing element of the NTC device must be located in the recess provided on the storage tank (ﬁgure 13).

The temperature and on-off programming of the domestic hot water supply are selected directly from the

boiler control panel, as described in this manual under the user instruction headings.

SAFETY

CONTACT

ROOM THERMOSTAT

Figure 13

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

14.3 DESCRIPTION OF THE ELECTRICAL CONNECTIONS TO THE BOILER

Turn the control box downward to access terminal board M2 used for the electrical connections by removing

the protective cover (see ﬁgure 13).

Terminals 1-2: connection of SIEMENS model QAA73 room temperature regulator supplied as optional extra.

Connection polarity is irrelevant.

The link ﬁtted across the “TA” terminals 3-4 must be removed.

Read the instructions supplied with this accessory for correct installation and programming procedures.

Terminals 3-4: “TA” room temperature thermostat connection. Thermostats with integral accelerator resistor

must not be used. Check that there is no voltage across the ends of the two thermostat connection wires.

Terminals 5-6: external safety contact (low voltage).

Terminals 7-8: connection of SIEMENS model QAC34 outdoor temperature sensor supplied as optional extra.

Read the instructions supplied with this accessory for correct installation procedures.

Terminals 9-10: connection of hot water temperature sensor supplied as optional extra for connecting hea-

ting-only boilers to an external water heater.

CLIP-IN AGU 2.511

Terminals 3-4 L-N OUT: connection to signal lamp (230 V - 0,5 A max) for lockout alarm.

Terminals 5-6 L-N OUT: connection to signal lamp (230 V - 0,5 A max) for run mode.

For low voltage signal lamp remove the internal wiring and feed with an external low voltage power supply.

(OPTIONAL EXTRA)

Figure 14

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

14.4 CONNECTING THE QAA73 TEMPERATURE REGULATOR

The SIEMENS model QAA73 room temperature regulator, if required (optional extra) must be connected to

terminals 1-2 of terminal board M2 in ﬁgure 13.

The link across terminals 3-4, provided for connection of a room temperature thermostat, must be removed.

The settings of the domestic hot water temperature and domestic hot water production schedule must be

made using this device.

The timed program of the central heating circuit must be set on the QAA73 if there is a single zone, or in relation

to the zone controlled by the QAA73 device.

The timed program for the central heating circuit of the other zones can be set directly on the boiler control

panel.

See the instructions provided with the QAA73 room temperature regulator for the user parameter programming

procedure.

IMPORTANT: For systems divided into zones, parameter 80 “HC2 curve”, which can be set on the QAA73

temperature regulator, must be set as _ _ . _ “not active”.

QAA73: parameters which can be set by the installation engineer (service)

By pressing the two PROG buttons together for at least three seconds it is possible to access the list of pa-

rameters that the installer can display and/or set.

Press either of these buttons to change the parameter to display or change.

Press the [+] or [-] key to change the value displayed.

Press either of the PROG buttons again to save the change.

Press the information button (i) to quit programming.

Here follows a list of the most commonly used parameters:

Line no. Parameter

Range

Default value

HC1 curve

2.5…40

Selection of central heating circuit temperature curve “kt”

HC1 max. output

25…85

Central heating system maximum output temperature

Type of building

Light, Heavy

on HC1

Light

Room compensation

On HC1

Activation/deactivation of the inﬂuence of the room temperature. If it is deactivated, the outdoor on HC2

temperature sensor must be installed.

on HC1+HC2

nil

Automatic adaptation of the temperature curve “kt” in relation to the room temperature.

On - off

0…360 min

Opt Start Max

Maximum time the boiler is switched on ahead of the timed program to optimise the temperature

in the premises.

Opt Stop Max

0…360 min

Maximum time the boiler is switched off ahead of the timed program to optimise the temperature

in the premises.

HC2 curve

2.5…40

—.- = not active

—.-

DHW Red Setp

Minimum temperature of the domestic hot water

10 or 35…58

DHW program

24 h/day

Selection of the type of timed program for domestic hot water.

TSP HC-1h

TSP HC

TSP DHW

24 h/day

= always on

PROG HC-1h

PROG HC

PROG DHW

= as HC1 central heating program less one hour

= as central heating program

= speciﬁc domestic hot water program (see also program lines 30-36)

- fault messages

In the event of fault, the display panel on the QAA73 shows the ﬂashing symbol . Press the information key

( ) to display the error code and a description of the fault (see Fault warning tables on paragraph 3.9).

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

14.5 CONNECTING THE OUTDOOR TEMPERATURE SENSOR

The SIEMENS model QAC34 outdoor temperature sensor (optional extra) for weather compensation must be

connected to terminals 7-8 of terminal board M2 in ﬁgure 13.

The procedures for setting the gradient of the temperature curve “kt” vary depending on the accessories

connected to the boiler.

a) Without QAA73 room temperature regulator:

The temperature curve “kt” must be selected by setting parameter H532 as described in section 16 “setting

the boiler parameters”.

See graph 2 for selecting the curve referred to a room temperature of 20°C.

The chosen curve can be shifted by pressing the

(2), button (2) on the boiler control panel, and modifying

keys. See graph 3 for curve selection. (The example show

the value displayed by pressing the

in graph 3 refers to the curve Kt=15).

and

Increase the value displayed if the room temperature required is not reached inside the premises for central

heating.

TM = Flow temperature

Te = Composite outside temperature

Sth = Kt Curve

Graph 2

Graph 3

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

b) With QAA73 room temperature regulator:

The temperature curve “kt” must be selected by setting parameter 70 “HC1 curve” of the QAA73 room tem-

perature control device as described in section 14.4 “QAA73: parameters which can be set by the installation

engineer (service)”.

See graph 4 for selecting the curve referred to a room temperature of 20°C.

The curve is shifted automatically on the basis of the room temperature set using the QAA73 climate con-

trol.

If the system is divided into zones, the temperature curve “kt” relating to the part of the system not control-

led by the QAA73 must be selected by setting parameter H532 as described in section 16 “setting the boiler

parameters”.

IMPORTANT: For systems divided into zones, parameter 80 “HC2 curve”, which can be set on the QAA73

room temperature regulator, must be set as _ _ . _ “not active” (see section 14.4).

TM = Flow temperature

Te = Composite outside temperature

Graph 4

c) With AGU2.500 for control of a low temperature system:

Refer to the instructions provided with the AGU2.500 accessories for connection and control of a low tem-

perature zone.

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

15. GAS VALVE ADJUSTMENT

Carry out the following operations in the given sequence:

1) Calibration of the maximum heat output. Check that the CO₂measured on the ﬂue, with the boiler operating

at the maximum heat output, is the same as that shown in table 1. Otherwise, turn the regulation screw (V) on

the gas valve. Turn the screw clockwise to reduce the concentration of CO₂and anticlockwise to increase it.

2) Calibration of reduced heat output. Check that the CO₂measured on the ﬂue, with the boiler operating at the

minimum heat output, is the same as that shown in table 1. Otherwise, turn the offset regulation screw (K) on

the gas valve. Turn the screw clockwise to increase the concentration of CO₂and anticlockwise to reduce it.

Pi:

Gas supply pressure connection point

P out: Gas pressure to burner connection point

Pressure connection point

for measurement of the OFFSET

Air signal input from fan

Pl:

Gas ﬂow adjuster screw max ﬁre

OFFSET adjuster screw min ﬁre

Figure 15

To simplify calibration of the gas valve, the “calibration function” can be set directly on the boiler control panel

by proceeding as follows:

1) Press the

keys (2-3) together until the display shows the pointer “ ” alongside the and symbols

(about 6 seconds) (see ﬁg. 16).

2) Press the

keys to set the fan speed at the minimum and maximum heat output (%PWM);

N.b - to set the minimum and maximum heat output quickly, press the

keys respectively;

3) press either of the two

keys to exit the function.

Figure 16

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

IMPORTANT: in the case of conversion from natural gas to propane (LPG), the following operations must be

performed before calibrating the gas valve as illustrated previously:

• Turn adjuster screw (V) on the gas valve through the number of complete revolutions speciﬁed in table 3.

G20 - 2H - 20 mbar

8.7 %

G31 - 3P - 37 mbar

10 %

CO₂max. heat output

CO₂min. heat output

8.4 %

9.8 %

Table 1

Gas consumption at 15 °C

1013 mbar

WH 46

WH 65

gas G20 - 2H - 20 mbar

PCI (MJ/Kg) NET

34.02

7.08

2.11

---

Consumption at max. heat output (Kg/h)

Consumption at min. heat output (Kg/h)

Gas nozzle (mm)

4.91

1.58

8.5

Table 2

Gas consumption at 15 °C

1013 mbar

WH 46

WH 65

gas G31 - 3P - 37 mbar

PCI (MJ/Kg) NET

46.34

3.60

1.16

8.5

46.34

5.20

1.55

---

Consumption at max. heat output (Kg/h)

Consumption at min. heat output (Kg/h)

Gas nozzle (mm)

Table 2.1

Model

Counter clockwise

turns of screw

(V)

WH 46

WH 65

4 ³/₄

Table 3

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

16. SETTING THE BOILER PARAMETERS

The boiler parameters may only be modiﬁed by professionally qualiﬁed staff proceeding as follows:

a) Press the

the display;

b) Press the

, keys on the boiler’s front panel together for about 3 s until the parameter H90 appears on

keys to select the parameter for modiﬁcation;

c) Press the and keys to modify the parameter;

d) Press the key to exit the programming function.

The following are the parameters generally used:

N° parametro

H90

Description

Factory setting

Setting for domestic hot water reduced temperature (°C)

D.H.W. (Domestic Hot Water) program

(0 = enabled; 1 = disabled)

H91

Maximum temperature (°C) of the central heating circuit HC1 corresponding to:

the main circuit in systems with just one zone;

the circuit of the zone where the QAA73 temperature control device is installed in case of

systems with more than one high-temperature zone;

the high temperature zone circuit in mixed systems and if the SIEMENS AGU2.500 accessory

is used.

H505

Maximum temperature (°C) of the central heating circuit HC2 of a system with more than one

zone, corresponding to the circuit of the low-temperature zone if the SIEMENS AGU2.500

accessory is used.

H507

H516

H532

Automatic Summer / Winter switching temperature (°C).

Selection of temperature curve of central heating circuit HC1 (see Graph 1)

Selection of temperature curve of central heating circuit HC2 (see Graph 1)

Maximum speed at maximum output in heating mode (rpm - maximum speed limitation)

Setting value of required speed (rpm) at low-ﬁre

H533

H536

H612

Refer to

paragraph 12.1

H536-H613

H541-H610

H544

Setting value of required speed (rpm) at high-ﬁre heating / domestic hot water mode

PWM (%) setting: maximum output in heating / domestic hot water mode

Pump post-circulation time in central heating mode (min)

H545

Burner operating pause time between two start-ups (s)

180

Hydraulic system setting (see instructions provided with the SIEMENS AGU2.500 accessory).

H552 = 50 with AGU2.500

H552 = 80 with RVA 47

H552

Conﬁguration of heating circuits

H553 = 12 with AGU2.500

H553

H615

Programmable function

Conﬁguration of system with low loss header P1

H632 = 00001111 with AGU2.500

H632 = 00001000 with storage tank without low loss header

H632

00001100

The value of Bit could be 1 or 0.

Press the keys 5 and 6 to select the bit to modify (b0 is the bit on the right, b7 is the last bit

on the left).

To modify the Bit value press on the keys 7 and 8

H641

H657

Fan post-purge interval (s)

Setpoint of autonomous ANTILEGIONELLA function

60...80 °C = setting temperature range

0 = function inactive

Table 4

If the electronic circuit board is replaced, make sure that the parameters set are those speciﬁc to the boiler

model, as indicated in the documentation available from the authorised Service Centre.

(*) For these parameters see section 13 (hydraulic system).

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

17. CONTROL AND OPERATION DEVICES

The boiler has been designed in full compliance with European reference standards and in particular is equip-

ped with the following

• Overheat thermostat

This thermostat interrupts the gas ﬂow to the main burner in case the water contained in the circuit has ove-

rheated. Under these conditions the boiler locks out and can only repeat the ignition procedure by pressing

of the reset button on the boiler after the cause of the trip has been rectiﬁed.

It is forbidden to disable this safety device

• Boiler circuit circulation test

The boiler electronic management unit is ﬁtted with a “boiler circulation test” function which involves con-

tinuously checking the primary circuit delivery and return temperatures. In case of an irregular increase in

the delivery and return temperature or a temperature reversal, the boiler stops and signals the error on the

display (see error table).

• Flue thermostat

This device, positioned on the ﬂue inside the boiler, interrupts the ﬂow of gas to the burner if the temperature

exceeds 90 °C. After verifying the cause of the trip, press the reset button positioned on the thermostat

itself, then press the reset button on the boiler.

It is forbidden to disable this safety device

• Flame ionization detector

The ﬂame sensing electrode guarantees safety of operation in case of gas failure or incomplete interlighting

of the main burner.

Under such conditions the boiler is locked out.

You must press the reset button on the boiler to restore the normal operating conditions.

• Supplementary pump overrun

After the burner has switched off due to a room thermostat intervention the preset pump overrun of the

pump lasts 10 minutes, when the boiler is in the central heating mode.

• Frost protection device

The boilers electronic management includes a “frost protection” function in the central heating system which

operates the burner to reach a heating ﬂow temperature of 30°C when the system heating ﬂow temperature

drops below 5 °C.

This function is enabled as long as the boiler is connected to the a.c. power supply gas supplies and the

pressure in the system is as speciﬁed.

• Pump-blocking prevention

In case there is no call for heat either from the central heating system or from the DHW system for 24 hours

on end the pump will automatically switch on for 10 seconds.

• Gas pressure switch

This device enables the main burner only to be switched on if the gas pressure is over 12 mbar.

• Hydraulic pressure sensor

This device enables the main burner only to be switched on if the system pressure is over 0.5 bar.

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

18. POSITIONING OF THE IGNITION AND FLAME SENSING ELECTRODE

Figure 17

19. CHECK OF COMBUSTION PARAMETERS

To measure the performance of combustion products, the forced draught boiler models are equipped with two

test points on the tapered coupling speciﬁcally designed for this purpose.

One of the two test points is connected to the exhaust ﬂue duct to allow measurements of the combustion

products and efﬁciency.

The second test point is connected to the comburant air inlet duct to check possible combustion products

circulation in case of coaxial ducts.

The exhaust ﬂue duct test point allows measurements of the following:

• combustion products temperature;

• concentration of oxygen (O₂) or, alternatively, of carbon dioxide (CO₂);

• concentration of carbon monoxide (CO).

The comburant air temperature must be measured at the test point connected to the air inlet duct.

ﬂue gas

combustion air

gasket

Figure 18

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

20. ACTIVATING THE CHIMNEY-SWEEP FUNCTION

To facilitate measurement of the combustion efﬁciency and improve the cleanliness of the production products,

the chimney sweep function can be activated by proceeding as described below:

1) Press the

(2-3) together until the pointer “ ” appears on the display alongside the symbol (about 3

seconds but no more than 6 seconds). In these conditions, the boiler operates at the maximum heat output

set for central heating.

2) Press either of the

buttons to exit the function.

Figure 19

21. ANNUAL SERVICE

To ensure the boiler operates at peak efﬁciency, the following checks must be performed every year:

• Check on the appearance and tightness of the gas and combustion circuit gaskets;

• Check on the condition and position of the ignition and ﬂame sensing electrodes (see section 18);

• Check on the condition of the burner and its ﬁxing to the aluminium ﬂange;

• Check for any dirt in the combustion chamber. Use a vacuum-cleaner for this cleaning operation,

• Check if the syphon trap is dirty;

• Check that the gas valve is calibrated correctly (see section 15);

• Check on the central heating system pressure.

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

22. BOILER SCHEMATIC

Figure 20

Legend:

Boiler drain point

Manometer (water pressure gauge)

Siphon (condensate)

NTC delivery heating probe

105°C overheat thermostat

Gas valve

Heat exchanger

Flame detector electrode (ionisation probe)

Main burner

Ignition electrode

Air/gas mixture header

Mixer with venturi

Injector

Fan

Flue thermostat

Flue spigot

Automatic air vent

Flue joint

Hydraulic pressure sensor

Pressure gas switch

NTC return heating probe

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

23. ILLUSTRATED WIRING DIAGRAM

INSTRUCTIONS PERTAINING TO THE INSTALLER

926.772.1 - GB/IE

24. TECHNICAL DATA

Boiler model WH

WH 46

WH 65

II2H3P