baxi Duo-tec 2 Combi 24 GA, Duo-tec 2 Combi 28 GA, Duo-tec 2 Combi 33 GA, Duo-tec 2 Combi 40 GA User guide

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Page 1

Installation & Servicing Instructions

Duo-tec 2 Combi GA Range

Gas Fired Wall Mounted Condensing

Combination Boiler

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

They must be read in conjunction with the Flue Installation Guide.

Page 2

Model Range

Baxi Duo-tec 2 Combi 24 GA

47-075-54

G.C.N

Baxi Duo-tec 2 Combi 28 GA

G.C.No 47-075-55

Baxi Duo-tec 2 Combi 33 GA

G.C.No 47-075-56

Baxi Duo-tec 2 Combi 40 GA

G.C.No47-075-57

The Benchmark Scheme

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit www.centralheating.co.uk for more information.

© Baxi Heating UK Ltd 2014 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner, except for permitted fair dealing under Copyrights, Designs and Patents Act 1988.

Applications for the copyright owner’s permission to reproduce or make other use of any part of this publication should be made, giving details of the proposed use, to the following address:

The Company Secretary, Baxi Heating UK Limited, Brooks House, Coventry Road, Warwick. CV34 4LL

Full acknowledgement of author and source must be given.

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. This can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly.

The Health & Safety Executive operates the ‘Gas Safe Register’, 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.

This company 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.

WARNING: Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages.

0085

ISO 9001

FM 00866

Page 3

Choose Building

Regulations Notification

Route

Installer Notification Guidelines

Competent Person's

Self Certification Scheme

Install and Commission this appliance to manufacturer's

instructions

Complete the

Benchmark Checklist

If you notify via the ‘Gas Safe

the Building Regulations

certificate on members’ behalf

Building Control

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact a government approved

inspector

Install and Commission this appliance to manufacturer's

instructions

Scheme Members only

Call ‘Gas Safe Register’ on:

0800 408 5577

or log onto:

www.gassaferegister.co.uk

within 10 days

You must ensure that the

certificate number issued by

the ‘Gas Safe Register’ is written

onto the Benchmark Checklist

‘Gas Safe Register’ will issue a

Building Regulations Compliance

Certificate to the property owner

and inform the relevant LABC

Complete the

Benchmark Checklist

LABC will record the data

and will issue a

certificate of compliance

Page 4

Legislation

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 Gas Safe 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”.

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.

This company declares 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 Gas Safe 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 Gas Safe registered engineers carry an ID card with their licence number and a photograph. You can check your engineer is registered by telephoning 0800 408 5500 or online at www.gassaferegister.co.uk

The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)

Regulations 1993 N

3083” 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 0086.

For GB/IE only.

All systems must be thoroughly flushed and treated with inhibitor (see section 6.2).

Codes of Practice - refer to the most recent version

In GB the following Codes of Practice apply: Standard Scope

BS 6891 Gas Installation. BS 5482 Part 1 Butane & Propane Gas Installation BS 5546 Installation of hot water supplies for domestic

purposes. BS EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings - Calculation of load. BS EN 14336 Installation & commissioning of water based

heating 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 EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings - Calculation of load. BS EN 14336 Installation & commissioning of water based

heating systems. BS 7074 Expansion vessels and ancillary equipment for

sealed water systems. BS 7593 Treatment of water in domestic hot water

central heating systems.

Page 5

Safe Manual Handling

General

The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.

Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health & Safety is the responsibility of EVERYONE.

There is no ‘safe’ limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.

Do not handle or lift unless you feel physically able.

Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.

Preparation

Co-ordinate movements - know where, and when, you are both going.

Minimise the number of times needed to move the boiler - plan ahead.

Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special care on ladders/into lofts.

Technique

When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body as possible.

Where possible transport the boiler using a sack truck or other suitable trolley.

Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the ‘Installation’ section of these instructions for recommended lift points.

Remember

The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.

If at any time when installing the boiler you feel that you may have injured yourself STOP !! DO NOT ‘work through’ the pain - you may cause further injury.

IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!

Page 6

CONTENTS

Section Page

1.0 Introduction 7

2.0 General Layout 8

3.0 Appliance Operation 9

4.0 Technical Data 10

5.0 Dimensions and Fixings 11

6.0 System Details 12

7.0 Site Requirements 15

8.0 Flue Options 20

9.0 Installation 22

10.0 Commissioning 27

11.0 Completion 31

12.0 Servicing 32

13.0 Changing Components 34

14.0 Combustion & Calibration 42

15.0 Electrical 43

16.0 Short Parts List 44

17.0 Fault Finding 45

18.0 External Low Voltage Controls 51

Benchmark Checklist 54

Page 7

Information Label

1.0 Introduction

1.1 Description

1. The Baxi Duo-tec 2 Combi GA Range are fully automatic gas fired wall mounted condensing combination boilers. 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

21.2 kW CH (Condensing)

28 models - 28 kW DHW

25.3 kW CH (Condensing)

33 models - 33 kW DHW

29.6 kW CH (Condensing)

40 models - 40 kW DHW

33.8 kW CH (Condensing)

3. The boiler is factory set for use on Natural Gas (G20). It can be converted to operate on Propane (G31) - see Section 10.1 ‘Gas Type Check’.

4. The boiler is suitable for use only on fully pumped sealed heating systems. Priority is given to domestic hot water.

Fig. 1

Control Flap

5. The boiler data badge gives details of the model, serial number and Gas Council number and is situated on the inner door panel. It is visible when the case front panel is removed (Fig. 2).

6. The boiler model, serial number and Gas Council number are also shown on the information label behind the boiler control flap (Fig. 1). This is for user reference.

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 one of the standard horizontal telescopic flue kits detailed in the Flue Installation Guide .

9. All systems must be thoroughly cleansed, flushed and

treated with inhibitor (see section 6.2).

1.2 Optional Extras

Various timers, external controls, etc. are available as optional extras. Full details are contained in the relevant sales literature.

Gas Type Label

Fig. 2

Data Badge

1.3 Contents of Pack

The pack contains:-

• Boiler

• Wall Plate inc. Taps

• Template

• Fittings & Literature Pack

NOTE: These Installation & Servicing Instructions MUST be read in conjunction with the Flue Installation Guide supplied in the Literature Pack.

Page 8

2.0 General Layout

2.1 Layout

1. Expansion Vessel

2. Expansion Vessel Valve

3. Primary Heat Exchanger

4. DHW Plate Heat Exchanger

5. Pump with Automatic Air Vent

6. Central Heating System Pressure Gauge

7. Fan Assembly

8. Air/Gas Collector

9. Flue Se nsor

10. Flame Sensing Electrode

11. Spark Ignition Electrode

12. Combustion Box Cover & Burner

13. Control Box Display

14. Condensate Trap

15. Safety Pressure Relief Valve

16. Drain Off Point

17. Gas Valve

18. Diverter Valve Motor

19. Boiler Controls

20. Boiler Adaptor

21. Heating Flow Sensor

22. Safety Thermostat

Page 9

3.0 Appliance Operation

3.1 Central Heating Mode

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

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.

Key

1. Pump with Automatic Air Vent

2. Boiler Drain Tap

3. Pressure Gauge

4. Safety Pressure Relief Valve

5. DHW Flow Sensor/Filter/Restrictor

6. Domestic Hot Water Priority Sensor

7. Domestic Hot Water NTC Sensor

8. Hydraulic Pressure Switch

9. Three Way Valve & Motor

10. Plate Heat Exchanger

11. Gas Valve

13. Heating Flow Sensor

14. Flue Sensor

15. Boiler Adaptor

16. Primary Heat Exchanger

17. Spark Ignition Electrode

18. Burner

19. Flame Sensing Electrode

20. Air/Gas Collector

21. Heating Return Sensor

22. Fan

23. Air/Gas Venturi

24. Expansion Vessel

12. Safety Thermostat (105° C)

Connections:A – Condensate Drain B – Heating Flow C – Domestic Hot Water Outlet D – Gas Inlet E – Cold Water Inlet On/Off Valve and filter F – Heating Return

Fig. 3

1. The frost protection mode is integral to the appliance and functions as long as there is power to the boiler, as indicated by the standby signal .

2. With CH & DHW or CH only selected, when the boiler temperature falls below 5°C the boiler will fire until a temperature of 30°C is reached.

3. If DHW only is selected, when the boiler CH temperature falls below 5°C the boiler will fire until a temperature of 30°C is reached. When the boiler DHW temperature falls below 5°C the boiler will fire until a temperature of 7°C is reached.

4. Further protection can be incorporated by using a system frost thermostat.

3.4 Pump Protection

1. If the boiler has been inactive for a period of 24 hours the pump will automatically operate for 1 minute to prevent sticking.

3.3 Boiler Frost Protection Mode

Page 10

4.0 Technical Data

4.1

Appliance Type C

13 C33 C43 C53

Appliance Category CAT I

Heat Input CH (Net) Max Min

24 model kW 20 3.5 28 model kW 24 3.9 33 model kW 28 4.8 40 model kW 32 5.9

Heat Output CH (Non-Condensing)

Max Min 24 model kW 20 3.4 28 model kW 24 3.8 33 model kW 28 4.7 40 model kW 32 5.7

Heat Output CH (Condensing)

Max Min 24 model kW 21.2 3.7 28 model kW 25.3 4.1 33 model kW 29.6 5.1 40 model kW 33.8 6.2

Heat Input DHW (Net) Max 24 model kW 24.7 28 model kW 28.9 33 model kW 34 40 model kW 41.2

Heat Output DHW Max 24 model kW 24 28 model kW 28 33 model kW 33 40 model kW 40

Injector

24 model mm 4.4 28 model mm 4.6 33 model mm 4.9 40 model mm 5.8

NATURAL GAS ONLY !

Max Gas Rate (Natural Gas - G20)

(After 10 mins)

24 model m3/h 2.54

28 model m 33 model m

/h 2.96

/h 3.49

40 model m3/h 4.23

Inlet Pressure (Natural Gas - G20)

mbar 20

PROPANE ONLY !

Max Gas Rate (Propane - G31)

(After 10 mins) 24 model kg/h 1.92 28 model kg/h 2.25 33 model kg/h 2.64 40 model kg/h 3.2

Inlet Pressure (Propane - G31)

mbar 37

NOTE: All data in this section are nominal values and subject to normal production tolerances.

2H 3P

Electrical Supply 230V~ 50H

(Appliance must be connected to an

earthed supply)

Power Consumption

24 model W 104 28 model W 116 33 model W 132 40 model W 142

Electrical Protection

IPX5D

External Fuse Rating 3A

Internal Fuse Rating F2L

Condensate Drain

To accept 21.5mm (3/4in) plastic waste pipe

Flue Terminal Diameter 100mm Dimensions Projection 125mm

Connections copper tails

Gas Inlet - 22mm Heating Flow - 22mm Heating Return - 22mm Cold Water Inlet - 15mm Hot Water Outlet - 15mm Pressure Relief Discharge - 15mm

Outercase Dimensions

Casing Height - 763mm Overall Height Inc Flue Elbow - 923mm Casing Width - 450mm Casing Depth - 355mm

Clearances

Above Casing 175 mm Min Below Casing 150 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

*This is MINIMUM recommended dimension. Greater clearance will aid installation and maintenance.

Weights

(24/28)

Packaged Boiler Carton 41.5kg Installation Lift Weight 36kg

(33)

Packaged Boiler Carton 43.5kg Installation Lift Weight 38kg

(40)

Packaged Boiler Carton 44.5kg Installation Lift Weight 39kg

SEDBUK Declaration

SAP 2005 Seasonal Efficiency for N. G.

models is 91.1%

SAP 2005 Seasonal Efficiency for L.P.G.

models is 93.2%

SAP 2009 Annual Efficiency for N. G.

models is 89%

SAP 2009 Annual Efficiency for L.P.G.

models is 91%

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

has been certified by 0087.

NOxClass 5

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 (24) (28) (33) (40)

l/min l/min l/min l/min DHW Flow Rate @ 30o C Rise 10.9 12.9 15.3 18.3

DHW Flow Rate @ 35o C Rise 9.8 11.5 13.5 16.4

Min Working DHW Flow Rate 2 2 2 2

IMPORTANT: Where Low Flow Taps or Fittings are intended to be used in the DHW system connected it is strongly recommended that the DHW flow rate DOES NOT fall below 2.5l/min. This will ensure reliable operation of the DHW function.

Expansion Vessel - (For Central Heating only. Integral with appliance)

bar

Min Pre-charge Pressure 0.5

(24 & 28) (33 & 40)

litre litre Max Capacity of CH System 125 155

Primary Water Content of Boiler (unpressurised) 2.5 2.8

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

Pump

Available Head See graph below

Pump - Available Head

5.5

4.5

3.5

2.5

Metre (wg)

1.5

0.5

200 400 600 800 1000 1200

Flow Rate (l/h)

Page 11

Dimensions

5.0 Dimensions and Fixings

At least 1.5°

A 763mm

B 355mm*

*This can be reduced to 345mm by removing the boiler control access flap

C 450mm

D 116mm Ø Min.

E 160mm

(207mm for 80/125mm flue systems)

360° Orientation

F 150mm

G 106mm

H 170mm

J 280mm

Boiler Side

Condensate

Drain

Flue Ø 100mm

Pressure

Relief Valve

(15mm)

Tap Rail

Boiler Side

50 mm

192 mm

Heating

Flow

(22mm)

65 mm 65 mm 65 mm 65 mm 95 mm45 mm

Hot Water

Outlet

(15mm)

Gas Inlet

(22mm)

Cold Water

Inlet

(15mm)

Heating

Return

(22mm)

Page 12

6.0 System Details

6.1 Information

1. The Baxi Duo-tec Combi HE GA Condensing Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN).

a) IRN 001 - See text of entry for installation

requirements and notes.

b) IRN 302 - Byelaw 14.

2. Reference to the WRc publications, ‘Water fittings and materials directory’ and ‘Water supply byelaws guide’ give full details of byelaws and the IRNs.

6.2 Treatment of Water Circulating Systems

1. All recirculatory water systems will be subject to corrosion unless they are flushed and an appropriate water treatment is applied. To prevent this, follow the guidelines given in BS 7593 “Treatment of Water in Domestic Hot Water Central Heating Systems” and the treatment manufacturers instructions.

2. Treatment must involve the use of a proprietary cleanser, such as Sentinel X300 or X400, or Fernox F3 and an inhibitor such as Sentinel X100 or Fernox MB-1.

3. Full instructions are supplied with the products, for further information contact Sentinel (0800 389 4670) or Fernox (0870 870 0362).

Failure to flush and add inhibitor to the system will invalidate the appliance warranty.

4. It is important to check the inhibitor concentration after installation, system modification and at every service in accordance with the inhibitor manufacturer’s instructions. (Test kits are available from inhibitor stockists.)

5. For information or advice regarding any of the above contact Technical Enquiries 0844 871 1555.

6.3 Bypass

1. The boiler is fitted with an automatic integral bypass. Some systems may require an additional external bypass.

6.4 System Control

1. Further external controls (e.g. room thermostat sensors) MUST be fitted to optimise the economical operation of the boiler in accordance with Part L of the Building Regulations (2010). A range of optional controls is available. Full details are contained in the relevant Sales Literature.

Page 13

6.0 System Details

6.5 System Filling and Pressurising

Fig. 4

Stop Valve

DHW Mains Inlet

Double Check Valve

Temporary Loop

Stop Valve

1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling.

2. A filling loop is supplied with the boiler. Follow the instructions provided with it.

3. The filling method adopted must be in accordance with all

Return

relevant water supply regulations and use approved equipment.

4. Your attention is drawn to: for GB: Guidance G24.2 and recommendation R24.2 of the Water Regulations Guide. for IE: the current edition of I.S. 813 “Domestic Gas Installations”.

5. The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe, provided a ‘Listed’ double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use.

6.6 Expansion Vessel (Central Heating only)

The end of the pipe should

terminate facing down and towards the wall

Fig. 6a

Filling Loop Connections

Fig. 5

1. The appliance expansion vessel is pre-charged to 0.5 bar. Therefore, the minimum cold fill pressure is 0.5 bar. The vessel is suitable for correct operation for system capacities up to 125 litres (24/28) or 155 litres (33/40). For greater system capacities an additional expansion vessel must be fitted. For GB refer to BS 7074 Pt 1. For IE, the current edition of I.S. 813 “Domestic Gas Installations”.

6.7 Safety Pressure Relief Valve (Fig. 6)

1. The pressure relief valve is set at 3 bar, therefore all pipework, fittings, etc. should be suitable for pressures in excess of 3 bar and temperature in excess of 100°C.

2. The pressure relief discharge pipe should be not less than 15mm dia, run continuously downward, and discharge outside the building, preferably over a drain. It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components. The end of the pipe should terminate facing down and towards the wall (Fig. 6a).

3. The discharge must not be above a window, entrance or other public access. Consideration must be given to the possibility that boiling water/steam could discharge from the pipe.

Pressure Relief Valve

Fig. 6

Discharge Pipe

Control Box removed for clarity

4. A remote relief valve kit is available to enable the boiler to be installed in cellars or similar locations below outside ground level (kit no. 5121379).

5. A boiler discharge pump is available, part no. 720648301. This pump will dispose of both condensate & high temperature water from the relief valve. It has a maximum head of 5 metres.

Page 14

Other Tap Outlets

Expansion Vessel*

Boiler

6.0 System Details

6.8 Domestic Hot Water Circuit (Fig. 7)

1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations.

2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. for IE: the current edition of I.S. 813 “Domestic Gas Installations”.

Fig. 7

Check Valve*

Pressure Reducer Valve*

Stop Tap

*See 6.8 for instances when these items may be required

To Hot Taps

IMPORTANT: Where Low Flow Taps or Fittings are intended to be used in the DHW system connected to a Baxi Duo-tec Combi GA it is strongly recommended that the DHW flow rate DOES NOT fall below 2.5l/min. This will ensure reliable operation of the DHW function.

3. The Water Regulations recommendations for England and Wales prohibits backflow from appliances into the wholesome water supply due to thermal expansion. However this type of instantaneous combination boiler, with less than 15 litres of stored capacity, does not require any backflow prevention device as any thermal expansion is accommodated within the appliance. It is possible in certain circumstances that other cold water demands (e.g. washing machines, flushing of W.C.s) may affect the DHW function of the boiler. In these instances the fitting of a backflow prevention device and expansion vessel is recommended.

4. Also if there is an existing check valve, loose jumpered stop cock, water meter or water treatment device already fitted to the wholesome water supply connected to the boiler domestic hot water (DHW) inlet supply then a suitable expansion device may be required.

5. The boiler’s maximum working mains pressure is 8 bar, therefore all pipework, connections, fittings, etc. should be suitable for pressures in excess of 8 bar. A pressure reducing valve must be fitted for pressures in excess of 8 bar. The manufacturer of any outlet fittings, such as a shower valve, may require a lower maximum pressure. The pressure reduction must take account of all fittings connected to the DHW system.

6.9 Showers

1. If a shower control is supplied from the appliance it should be of the thermostatic or pressure balanced type. Thermostatic type shower valves provide the best comfort and guard against water at too high a temperature. Existing controls may not be suitable - refer to the shower valve manufacturer.

6.10 Hard Water Areas

1. If the area of the installation is recognised as a HARD WATER AREA then a suitable device should be fitted to treat the mains water supply to the boiler. Contact your Water Distribution Company for advice on suitable devices.

Page 15

5mm Min

450mm

5mm Min

175 mm Min (300mm

Min if using 80/125mm

flueing system)

763mm

7.0 Site Requirements

7.1 Location

1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (The boiler may be fitted inside a cupboard-see Section 7.3).

2. Where the boiler is sited in an unheated enclosure and during periods when the heating system is to be unused it is recommended that the permanent live is left on to give BOILER frost protection. NOTE: THIS WILL NOT PROTECT THE SYSTEM !

3. If the boiler is fitted in a room containing a bath or shower reference must be made to the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of I.S. 813 “Domestic Gas Installations” and the current ETCI rules.

Fig. 8

450mm Min

For Servicing

Purposes

150mm* Min

At least 1.5°

4. If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE/UP/7 (Gas Installations in Timber Framed Housing).

7.2 Clearances (Figs. 8 & 9)

1. A flat vertical area is required for the installation of the boiler.

2. These dimensions include the necessary clearances around the boiler for case removal, spanner access and air movement. Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler.

*This is MINIMUM recommended dimension. Greater clearance will aid installation and maintenance.

7.3 Ventilation of Compartments

1. Where the appliance is installed in a cupboard or compartment, no air vents are required.

5mm Min

In Operation

Fig. 9

2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.

355mm

(345mm with flap removed)

Page 16

7.0 Site Requirement

7.4 Gas Supply

1. The gas installation should be in accordance with the relevant standards. In GB this is BS 6891 (NG) or BS 5482 Pt. 1 (LPG). In IE this is the current edition of I.S. 813 “Domestic Gas Installations”.

2. The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock (Fig. 10).

3. Ensure that the pipework from the meter to the appliance is of adequate size, and the demands of any other gas appliances in the property are taken into consideration. Do not use pipes of a smaller diameter than the boiler gas connection (22mm).

Fig. 10

Zone 1

Zone 0

Window Recess

Zone 2

Fig. A

Zone 2

Window Recess

Zone 2

0.6 m

In GB Only

Window Recess Zone 2

Gas Service Cock

Outside Zones

Ceiling

7.5 Electrical Supply

1. External wiring must be correctly earthed, polarised and in accordance with relevant regulations/rules. In GB this is the current I.E.E. Wiring Regulations. In IE reference should be made to the current edition of ETCI rules.

2. The mains supply is 230V ~ 50Hzfused at 3A.

NOTE: The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance.

Connection may be via a fused double-pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only.

7.6 Bath & Shower Rooms

1. If the boiler is fitted in a room containing a bath or shower it can be fitted in zone 2, (Figs. A & B shows zone dimensions for a bathtub. For other examples refer to the Current I.E.E. Wiring Regulations) reference must be made to the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of I.S. 813 “Domestic Gas Installations” and the current ETCI rules.

Zone 1

Zone 0

Fig. B

Zone 2

0.6 m

2.25 m

In GB Only

Page 17

Examples are shown of the following methods of termination:i) to an internal soil & vent pipe ii) via an internal discharge branch (e.g. sink waste) downstream of the trap iii) to a drain or gully iv) to a purpose made soakaway v) pumped into an internal discharge branch (e.g. sink waste) downstream of the trap vi) pumped into an external soil & vent pipe vii) to a drain or gully with extended external run & trace heating

It is strongly recommended to discharge internally into the household drainage system. If connecting to a rain water drain, that drain MUST discharge into a foul drain.

50mm per metre of pipe run

2.5° Minimum fall

Boiler

Sink

Boiler

50mm per metre of pipe run

2.5° Minimum fall

50mm per metre of pipe run

2.5° Minimum fall

21.5mm

i) Termination to an internal soil and vent pipe

450mm min*

ii) External termination via internal discharge branch

iii) Termination to a drain or gully

32mm

*450mm is applicable to properties up to 3 storeys. For multi-storey building installations consult BS 6798.

e.g sink waste - downstream*

Pipe must terminate above water level but below surrounding surface. Cut end at 45°

Insulation

Pipe must terminate above water level but below surrounding surface. Cut end at 45°

*It is NOT RECOMMENDED to connect upstream of the sink or other waste water receptacle !

7.0 Site Requirements

7.7 Condensate Drain

FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER.

CAREFUL CONSIDERATION MUST BE GIVEN TO THE POSSIBILITY OF THE PIPEWORK BEING SUBJECT TO FREEZING CONDITIONS AND APPROPRIATE MEASURES TAKEN TO PREVENT BLOCKAGE. CORRECT INSTALLATION IN ACCORDANCE WITH THIS SECTION WILL CONSIDERABLY MINIMISE THE LIKELIHOOD OF BLOCKAGE AND SUBSEQUENT BOILER LOCK-OUT.

A CONDENSATE DISCHARGE PUMP AND PIPE ‘TRACE HEATING’ ARE AVAILABLE AS ACCESSORIES - see paragraphs 7.7.12 to 7.715 for further details.

The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST

2.5° (50mm per metre) along the entire run EXCEPT when employing a suitable condensate pump in basement and cellar or similar applications.

The boiler condensate trap incorporates a seal of 75mm, therefore it is unnecessary to install an air break and trap in the discharge pipework.

1. The condensate outlet will accept 21.5mm ( overflow pipe. It is strongly recommended that this discharges internally into the household drainage system. Where this is not possible, discharge into an outside drain is permissible providing every possible precaution is taken to prevent freezing.

2. Ensure the discharge of condensate complies with any national or local regulations in force. BS 6798 & Part H1 of the

Building Regulations give further detailed guidance.

3. The discharge pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP.

4. Metal pipework is NOT suitable for use in condensate discharge systems.

5. The pipe should be a minimum of 21.5mm diameter and must be supported using suitably spaced clips of the correct design to prevent sagging.

6. It is advisable that the full length of condensate pipe is run

internally and preferably be less than 3 metres.

/4in) plastic

Boiler

50mm per metre of pipe run

2.5° Minimum fall

iv) Termination to a purpose made soakaway

Further specific requirements for soakaway design are referred to in BS 6798.

500mm min

Holes in the soak-away must face away from the building

7. Internal runs greater than 3 metres or runs in cold areas

should use 32mm waste pipe.

8. External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external use.

9. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run and sized and insulated accordingly.

10. In all cases discharge pipe must be installed to aid disposal of the condensate. To reduce the risk of condensate being trapped, as few bends and fittings as possible should be used and any burrs on cut pipe removed.

11. When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC's are flushed or sinks emptied then back-pressure may force water out of the boiler trap and cause appliance lockout.

Page 18

v) pumped into an internal discharge branch

(e.g. sink waste) downstream of the trap

50mm per metre of pipe run

Sink

2.5° Minimum fall

Basement or similar (heated)

Boiler

Condensate Pump

vi) pumped into an external soil & vent pipe

50mm per metre of pipe run

Pipe must terminate above water level but below surrounding surface. Cut end at 45°

7.0 Site Requirements

7.7 Condensate Drain (cont.)

12. A boiler discharge pump is available, ‘MULTIFIT’ part no. 720648301. This pump will dispose of both condensate & high temperature water from the relief valve. It has a maximum head of 5 metres. Follow the instructions supplied with the pump.

13. Condensate Drain Pipe ‘Trace Heating’ Elements are available in various lengths. ‘MULTIFIT’ part nos.:-

1 metre 720644401 2 metre 720664101 3 metre 720664201 5 metre 720664401*

*Where the drain is between 3 & 5 metres a 5 metre kit can be used and “doubled back” upon itself.

14. It is possible to fit the element externally on the condensate drain or internally as detailed in the instructions provided.

15. The fitting of a ‘Trace Heating’ Element is NOT a substitute for correct installation of the condensate drain. ALL requirements in this section must still be adhered to.

Unheated Location (e.g. Garage)

Boiler

2.5° Minimum fall

Basement or similar (heated)

Condensate Pump

vii) to a drain or gully with extended

external run & trace heating

The ‘Trace Heating’ element must be installed in accordance

Boiler

with the instructions supplied. External runs & those in unheated locations still require insulation.

50mm per metre of pipe run

2.5° Minimum fall

Pipe must terminate above water level but below surrounding surface. Cut end at 45°

Page 19

300 min

Terminal Assembly

Top View Rear Flue

Property Boundar y Line

Terminal Position with Minimum Distance (Fig. 12) (mm)

A1Directly below an opening, air brick, opening

windows, etc. 300 B1Above an opening, air brick, opening window etc. 300 C1Horizontally to an opening, air brick, opening window etc. 300 D2Below gutters, soil pipes or drain pipes. 25 (75) E2Below eaves. 25 (200) F2Below balconies or car port roof. 25 (200) G2From a vertical drain pipe or soil pipe. 25 (150) H2From an internal or external corner. 25 (300) I Above ground, roof or balcony level. 300 J From a surface or boundary line facing a terminal. 600 K From a terminal facing a terminal (Horizontal flue). 1200

From a terminal facing a terminal (Vertical flue). 600 L From an opening in carport (e.g. door, window)

into the dwelling. 1200 M Vertically from a terminal on the same wall. 1500 N Horizontally from a terminal on the same wall. 300 R From adjacent wall to flue (vertical only). 300 S From an adjacent opening window (vertical only). 1000 T Adjacent to windows or openings on pitched and flat roofs 600 U Below windows or openings on pitched roofs 2000

7.0 Site Requirements

7.8 Flue

NOTE: Due to the nature of the boiler a plume of water

vapour will be discharged from the flue. This should be taken into account when siting the flue terminal.

1. The following guidelines indicate the general requirements for siting balanced flue terminals. For GB recommendations are given in BS 5440 Pt 1. For IE recommendations are given in the current edition of I.S. 813 “Domestic Gas Installations”.

2. If the terminal discharges onto a pathway or passageway, check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway.

In addition, the terminal should be no nearer than 150 mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.

Only ONE 25mm clearance is allowed per installation. If one of the dimensions D, E, F, G or H is 25mm then the remainder MUST be as shown in brackets, in accordance with B.S.5440-1.

NOTE: The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below

Plume Displacement Kit

Fig. 11

J,K

Air Inlet

3. If a terminal is less than 2 metres above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be provided.

IMPORTANT:

• Under car ports we recommend the use of the plume displacement kit.

• The terminal position must ensure the safe and nuisance - free dispersal of combustion products.

*4. Reduction to the boundary is possible down to 25mm but flue deflector part no. 5111068 must be used.

IMPORTANT: If fitting a Plume Displacement Flue Kit, the air inlet must be a minimum of 150mm from any opening windows or doors (see Fig. 13).

Likely flue positions requiring a flue terminal guard

Opening Window or Door

150mm MIN.

Fig. 13

J,K

Fig. 12

Page 20

Plume Displacement Kit 60 /100 dia 1M Extensions 45° & 93° elbows are also available - see the separate Flue Guide.

Horizontal Flues

8.0 Flue Options

8.1 Horizontal Flue Systems

1. The standard flue is suitable only for horizontal termination applications.

(ii)

(i)

2. All fittings should be fully engaged. The approximate engagement is 40mm. Apply the lubricant supplied to the seal on each fitting to aid assembly.

3. Maximum permissible equivalent flue lengths are:(60/100) (80/125)

Horizontal Concentric 10 metres 20 metres

4. Any additional “in line” bends in the flue system must be

taken into consideration. Their equivalent lengths are:Concentric Pipes:

135° bend 0.5 metres 93° bend 1.0 metres

5. The elbow supplied with the standard horizontal

telescopic flue kit is not included in any equivalent length calculations.

NOTE: Flue length is measured from point (i) to (ii) as shown.

IMPORTANT SUPPORT - All flue systems MUST be securely supported a MINIMUM of once every metre. It is recommended that every straight piece is supported irrespective of length. Additional supports are available as accessories. VOIDS - Consideration must be given to flue systems in voids and the provision of adequate access for subsequent periodic visual inspection.

NOTE: Horizontal flue pipes should always be installed with a fall of at least 1.5°

from the terminal to allow condensate to run back to the boiler.

This bend is equivalent to 1 metre

This bend is equivalent to

(i)

1 metre

Total equivalent length =

A+B+C+2 x 90° Bends

6. Read this section in conjunction with the Flue Installation

Guide supplied with the boiler.

(ii)

Page 21

315mm

500mm

Fig. 14

Flue Deflector

Fig. 16

8.0 Flue Options

8.2 Flue Lengths

The standard horizontal telescopic flue kit allows for lengths between 315mm and 500mm from elbow to terminal without the need for cutting (Fig. 14). Extensions of 250mm, 500mm & 1m are available.

The maximum permissible equivalent flue length is:

10 metres (60/100 system - vertical & horizontal) 20 metres (80/125 system - vertical & horizontal) 15 metres (80/80 twin pipe)

8 metres (60/100 system - vertical connected

to ridge terminal)

8.3 Flue Trim

1. The flexible flue trims supplied can be fitted on the outer and inner faces of the wall of installation.

8.4 Terminal Guard (Fig. 15)

Fig. 15

1. When codes of practice dictate the use of terminal guards ‘Multifit’ accessory part no. 720627901 can be used (Note: This is not compatible with Flue Deflector referred to below).

2. There must be a clearance of at least 50mm between any part of the terminal and the guard.

3. When ordering a terminal guard, quote the appliance name and model number.

4. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated.

8.5 Flue Deflector (Fig. 16)

1. Push the flue deflector over the terminal end. It may point upwards as shown, or up to 45° either way from vertical. Secure the deflector to the terminal with screws provided.

8.6 Flue Accessories

1. For full details of Flue Accessories (elbows, extensions, clamps etc.) refer to the Flue Installation Guide supplied in the literature pack.

Page 22

150mm

For Side Flue Exit

Fig. 18

Fig. 17

175 mm Minimum Clearance

5 mm Minimum Side Clearance

Profile of Outercase

Part No. 720636602

116mm Dia Minimum

Aperture For Flue Tube

Boiler Mounting Bracket Fixing Slots

Ø 8 mm

Vertical Flue

Centre Line

Ø 8 mm

Side Flue

Centre Line

177 mm

50 mm

5 mm Minimum Side Clearance

9.0 Installation

9.1 Unpacking & Initial Preparation

IMPORTANT RISK ASSESSMENT - Before commencing the installation it is recommended that the ‘Five Steps to Risk Assessment’ document published by the HSE is consulted, and an assessment performed as described. GAS SUPPLY - The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4).

NOTE: A small amount of water may drain from the boiler

in the upright position. If pre-plumbing it will be necessary to turn the carton over to access the wall plate first.

1. Remove staples, open flaps and remove the cardboard

sheet. Remove the polystyrene side pieces and literature. Two people can then lift out the boiler (Fig. 17).

2. After considering the site requirements

(see Section 7.0) position the fixing template on the wall ensuring it is level both horizontally and vertically.

3. Mark the position of the two most suitable fixing slots for

the wall plate and boiler lower fixing holes.

4. Mark the position of the centre of the flue hole (rear exit).

For side flue exit, mark as shown (Fig. 18).

5. If required, mark the position of the gas and water pipes.

Remove the template.

3/4” BSP

Connections

Wall Template

Flushing Tube

Condensate

Drain

65 mm 65 mm 65 mm 65 mm

45 mm

50 mm

200 mm

Recommended

150 mm Minimum Clearance

Gas

Hot Water

Heating

Flow

(22mm)

Cold Water

Inlet

Outlet

(22mm)

(15mm)

Flow Restrictor (40 kW model only)

Inlet

(15mm)

Pressure

Relief Valve

(15mm)

95 mm

Heating Return (22mm)

Fig. 19

Part No. 720636602

6. Cut the hole for the flue (minimum diameter 116mm).

7. Drill the wall as previously marked to accept the wall plugs supplied. Secure the wall plate using the fixing screws.

8. Using a spirit level ensure that the plate is level before finally tightening the screws.

9. Connect the gas and water pipes to the valves on the wall plate using the copper tails supplied. Ensure that the sealing washers are fitted between the connections.

NOTE: 40kW models ONLY - ensure the flow restrictor is inserted in cold water inlet connection (Fig. 19). On other models the restrictor is factory fitted internally.

10. Fit the filling loop as described in the instructions supplied with it.

9.2 Flushing

1. Connect a tube to the heating flow or return pipe (Fig. 20).

2. Flush thoroughly (see System Details, Section 6.2).

Heating Flow

Fig. 20

Heating Return

Page 23

Boiler Mounting

Bracket

Sealing Washers

9.0 Installation

9.3 Fitting The Boiler

1. Remove the sealing caps from the boiler connections.

NOTE: A small amount of water may drain from the boiler once the caps are removed.

2. Lift the boiler as indicated by the shaded areas. The boiler should be lifted by TWO PEOPLE. Engage the mounting bracket at the top rear of the boiler on the wall plate (Fig. 21) (see Safe Manual Handling page 5).

3. Insert the sealing washers between the valves and pipes on

the wall plate and the boiler connections. Tighten all the connections.

Suggested Lifting Points shown as shaded area

Fig. 22a

Pressure Relief Valve

Fig. 21

Remove Sealing Caps from under the Boiler before lifting into position

Prime Trap by pouring

300ml of water into

flue spigot

9.4 Fitting the Safety Pressure Relief Discharge

Pipe (Fig. 22)

1. Remove the discharge pipe from the kit.

2. Determine the routing of the discharge pipe in the vicinity of the boiler. Make up as much of the pipework as is practical, including the discharge pipe supplied.

IMPORTANT: Make all soldered joints before connecting to the pressure relief valve. The relief valve is intentionally angled to the right of the boiler. DO NOT adjust the position of the valve. The discharge pipe must be installed before pressurising the system.

3. The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building. See section 6.7 for further details.

4. Utilising one of the sealing washers, connect the discharge pipe to the adaptor and tighten the nut hand tight, plus 1/4 turn to seal.

5. Complete the discharge pipework and route it to the outside discharge point.

Fig. 22

Condensate Trap Outlet Connection

Discharge Pipe

Control Box removed for clarity

Rubber Hose

Fig. 23

9.5 Condensate Drain (see section 7.7) (Fig. 23)

1. Using the short piece of rubber hose supplied, connect the condensate drain pipework to the boiler condensate trap outlet pipe. When connecting the hose, ensure that the condensate sump is not inadvertently unscrewed,

Ensure the discharge of condensate complies with any national or local regulations in force (see British Gas “Guidance Notes for the Installation of Domestic Gas Condensing Boilers” & HHIC recommendations).

2. The hose will accept 21.5mm (

/4in) plastic overflow pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain is acceptable.

3. The boiler condensate trap should be primed by pouring approximately 300ml of water into the flue spigot (Fig. 22a). Do not allow any water to fall into the air inlet.

Page 24

500mm

9.0 Installation

Wall Thickness

(X)

Fig. 25

315mm

Connection Assembly

(X)

Terminal Assembly

Fig. 24

Wall

Thickness

9.6 Fitting The Flue

HORIZONTAL TELESCOPIC FLUE

1. There are two telescopic sections, the Terminal Assembly and the Connection Assembly, a roll of sealing tape and two self tapping screws. A 93° elbow is also supplied.

2. The two sections can be adjusted to provide a length between 315mm and 500mm (Fig. 24) when measured from the flue elbow (there is 50mm engagement into the elbow).

3. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (Fig. 25).

NOTE: The flue elbow is angled at 93 degrees to ensure a fall back to the boiler.

4. Measure the distance from the outside wall face to the elbow. This dimension will be known as ‘X’ (Fig. 25).

5. If the distance from the flue elbow to the outside face of the wall (‘X’ in Fig. 25) is less than 250mm the Connection Assembly can be discarded and the Terminal Assembly fitted directly into the elbow.

6. In instances where the dimension ‘X’ (Fig. 25) is between 250mm and 315mm it will be necessary to shorten the Terminal Assembly by careful cutting to accommodate walls of these thicknesses.

7. To dimension ‘X’ add 50mm. This dimension to be known as ‘Y’.

Dimension ‘Y’

‘TOP’ Label

Fig. 27

Fig. 26

‘TOP’ Label

Sealing Tape

‘Peak’ to be uppermost

8. Adjust the two telescopic sections to dimension ‘Y’ and seal the joint with the tape provided (Fig. 27). Ensure that the labels marked ‘TOP’ on the Terminal and Connection Assemblies are uppermost.

9. Using the clearance holes in the Connection Assembly secure it to the Terminal Assembly using the screws supplied (Fig. 28).

Securing Screw

Fig. 28

Page 25

Apply the lubricant supplied for ease of assembly (do not use any other type).

Ensure Flue Elbow is fully engaged into Boiler Adaptor

Flue Elbow

Boiler Adaptor

Fig. 29

9.0 Installation

9.6 Fitting the Flue (Cont)

10. Remove the flue elbow and insert the flue through the hole in the wall.

11. Refit the elbow to the boiler adaptor, ensuring that it is pushed fully in (Fig. 29).

12. Two flue trims are supplied, one for internal use, the other for outside. The internal trim is packaged and identified as such - it should not be used externally.

13. It is recommended that if the internal trim is being used it is first fitted over the elbow to allow access to the securing screws and then manouvered into place against the wall.

Apply the lubricant supplied for ease of assembly (do not use any other type).

Ensure Flue is fully engaged into Elbow

Flue to elbow

securing screws

Elbow to adaptor

securing screws

Trims

14. Draw the flue back through the wall and engage it in the elbow. It may be necessary to lubricate to ease assembly of the elbow and flue (Fig. 30).

15. Ensure that the terminal is positioned with the slots to the bottom (Fig. 31). Secure the flue to the elbow with the screws supplied (Fig. 30).

16. Secure the elbow flue to the boiler adaptor with the screws supplied in the boiler fittings pack (Fig. 30).

IMPORTANT: It is essential that the flue terminal is fitted as shown to ensure correct boiler operation and prevent water entering the flue.

Fig. 30

17. Make good between the wall and air duct outside the building, appropriate to the wall construction and fire rating.

18. If necessary fit a terminal guard (see Section 8.4).

Slots at bottom

Fig. 31

Page 26

Control Box

9.0 Installation

9.7 Making The Electrical Connections

1. Undo the securing screws and lift the case front panel off.

2. Disengage the securing tab and hinge the control box downwards. Undo the terminal block cover securing screw and remove the cover (Fig. 34).

3. Slacken the gland nut in the left of the boiler lower panel and pass the mains cable through it. Remove the grommet adjacent to the gland nut, pierce the diaphragm and insert the cable from the external control system.

4. Leave sufficient slack in the cables to allow the Control Box to be hinged fully open. Tighten the gland nut and refit the grommet.

5. Connect the Earth, Permanent Live and Neutral wires to the terminal strip.

Fig. 35

Fused Spur

Fig. 34

NOTE: Both the Permanent Live and Neutral

connections are fused.

6. Refer to the instructions supplied with the external control(s).

IMPORTANT: Any thermostat MUST be suitable for

Room ‘Stat

230V switching.

7. Remove the link between terminals 1 & 2. The 230V

supply at terminal 2 must be connected to the thermostat. The switched output from the thermostat must be

g/y

connected to terminal 1. (Figs. 35 & 36). If the room thermostat being used incorporates an anticipator it MUST

230V

be wired as shown in Figs. 35 & 36.

NOTE: When only Low Voltage controls are being used (connected to Terminal M2) it is still necessary to remove the link wire !

8. Replace the terminal block cover.

Frost T hermostat

Room ‘Stat

230V

Pipe T hermostat

9. See Section 18.0 for details of fitting the Optional Outdoor Sensor.

9.8 Preliminary Electrical Checks

Fig. 36

NOTE: The 230V switched signal for external controls

(Frost Stat - Room Stat - Timer) must always be taken from terminal 2 at the boiler. Live, Neutral and Earth to power these controls must be taken from the Fused Spur.

External Clock

230V

g/y

1. Prior to commissioning the boiler preliminary electrical system checks should be carried out.

2. These should be performed using a suitable meter, and include checks for Earth Continuity,

Resistance to Earth, Short Circuit and Polarity.

Page 27

10.0 Commissioning

bar

Fig. 37

Pump

Cap

Automatic Air

Vent

Fig. 38

Control Box removed for clarity

Heating

Pressure Gauge

10.1 Commissioning the Boiler

1. Reference should be made to BS:EN 12828, 12831 & 14336 when commissioning the boiler. Ensure that the trap has been primed -see Section 9.5.3.

2. At the time of commissioning, complete all relevant sections of the Benchmark Checklist at the rear of this publication.

3. Open the mains water supply to the boiler and all hot water taps to purge the DHW system.

4. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler. Ensure that the cap on the automatic air vent on the pump body is opened (Fig. 37).

5. The system must be flushed in accordance with BS 7593 (see Section 6.2) and the flushing agent manufacturers instructions.

6. Pressurise the system to 1.5 bar (Fig. 38) then close and disconnect the filling loop.

7. Test for gas tightness, turn the gas supply on and purge according to in GB BS 6891 and in IE I.S. 813 "Domestic Gas Installations".

De-Aeration Function

8. When power is supplied to the boiler for the first time the software will be displayed, followed by . However if is shown, press for 2 to 4 seconds. will now be displayed.

Fig. 39

Display showing Gas

Type Recognition

9. Press & together and hold for at least 6 seconds. The ‘De-Aeration’ Function will be activated and

‘On’ displayed.

10. The boiler pump will run for up to 10 minutes during which time the diverter valve will switch between heating & hot water. This will purge air from the system. The display will show .

Gas Type Check

11. Once de-aeration is complete the boiler will go automatically

to first fire-up and run at the Ignition Phase fan speed for 3 or 4 IMPORTANT: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type specified on the appliance data plate. No measurement of the combustion is necessary.

Do not adjust the air/gas ratio valve. During the Gas Type Check Function the combustion ratio will increase for a short time while the gas type is established.

FUNCTION INTERRUPTION

If either De-aeration or Gas Check is interrupted by a fault e.g. low water pressure (E118) or air in the gas supply (E128 or E133) the fault must be rectified and the function reactivated. During De-aeration, if water pressure is lost, repressurising to 1.0 bar will allow the function to continue. Whilst the Gas Type Check is being performed if

minutes to check the gas type (N.G. or Propane L.P.G.). The boiler

software checks the combustion value against the set value.

will be displayed, alternating with a figure representing the

Ignition Phase speed, e.g.

‘33’ or ‘43’(Note: Each boiler model

will display a different figure).

12. The boiler is factory set for Natural Gas. On a Natural Gas

Supply will be displayed and the boiler is ready for the Inlet

Pressure & Gas Rate to be checked (Section 10.2).

13. IMPORTANT - In cases where the supplied gas is Propane

gas will be displayed. Press for at least 6 seconds to

confirm that this is the intended gas type for the installation.

14. IF THE BOILER IS TO BE OPERATED ON PROPANE A

SUITABLE PERMANENT MARKER PEN MUST BE USED TO

ALTER THE ‘GAS SETTING INFORMATION’ LABEL ADJACENT

TO THE DATA LABEL ! water pressure is lost the function can be reactivated by

repressurising then pressing & together and holding for at least 6 seconds. If a gas supply fault occurs

must be pressed before & .

15. Having checked:

• That the boiler has been installed in accordance with these instructions.

• The integrity of the flue system and the flue seals.

• The integrity of the boiler combustion circuit and the relevant seals.

Perform the combustion check.

Page 28

Plug

Analyser Probe

Flue Sampling

Point

10.0 Commissioning

10.2 Checking the Combustion - ‘Chimney Sweep’

Function

1. To set the boiler to operate at MAXIMUM and MINIMUM, press & together and hold for at least 6 seconds. ‘On’ will be displayed briefly, followed by ‘304’ then the boiler output expressed as percentage i.e. ‘100’.

Fig. 36a

2. Press until ‘00’ is displayed, indicating minimum input.

3. To exit the function press & together for 6 seconds.

4. The combustion (CO level and CO/CO2 ration) must be measured and recorded at MAXIMUM DHW input and MINIMUM input.

5. Follow the flow chart on the next page to comply with the requirement to check combustion on commissioning.

6. The system MUST be cold to ensure the boiler is operating under full demand

Page 29

Verify Flue Integrity

Indication that products of combustion & inlet air are mixing - further investigation is required. Check all flue components are correctly assembled, fixed & supported. Check the flue & terminal are unobstructed.

Is O

2  20.6% and

2 < 0.2% ?

TURN APPLIANCE OFF !

Call 0844 871 1555 for advice. The appliance MUST NOT be commissioned until all problems are identified and resolved.

Set Boiler to Maximum Rate

(see 10.3.1) Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser.

Perform Flue Integrity Combustion Check

Insert the analyser probe into the air inlet test point, allowing the reading to stabilise.

Is O

2  20.6% and

2 < 0.2% ?

Yes

Verify Integrity of Seals

Check all burner seals, internal flue seals, door & case seals. Replace any seals that appear unsound.

Is CO < 350ppm and CO/CO

0.004 ?

2 ratio <

Check CO & Combustion Ratio at Maximum Rate

Whilst the boiler is still

Yes

operating at maximum insert the analyser probe into the flue gas test point, allowing the reading to stabilise.

Is CO < 350ppm and CO/CO < 0.004 ?

Yes

10.0 Introduction

10.2 Checking the Combustion - ‘Chimney Sweep’

Function (cont)

1. Follow the flow chart opposite.

Set Boiler to Minimum Rate

(see 10.3.2)

2 ratio

Yes

Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser.

Check CO & Combustion Ratio at Minimum Rate

Whilst the boiler is operating at minimum insert the analyser probe into the flue gas test point, allowing the reading to stabilise.

TURN APPLIANCE OFF !

Call 0844 871 1555 for advice. The appliance MUST NOT be commissioned until all problems are identified and resolved. If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with the GSIUR. Note: Check & record the CO & combustion ratio at both maximum & minimum rates before calling 0844 871 1555.

Is CO < 350ppm and CO/CO

2 ratio <

0.004 ?

Yes

BOILER OPERATING

SATISFACTORILY. NO

FURTHER ACTION

REQUIRED

Ensure test points are capped, the boiler case front panel is correctly fitted & secured and all other commissioning procedures completed. Complete the ‘Benchmark’ Checklist, recording the CO & combustion ratio readings as required.

Page 30

DO NOT check gas pressure here

10.0 Commissioning

10.3 Check the Operational (Working) Gas Inlet

Pressure & Gas Rate

Note: The system MUST be cold to ensure the boiler is

operating under full demand. To obtain an accurate measurement on smaller capacity systems it may be necessary to open one or more hot taps in order to maintain the boiler at full rate.

1. Press & together and hold for at least 6 seconds. then ‘100’ when the boiler is lit, indicating the CH output is at MAXIMUM (‘Chimney Sweep Function’).

2. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point on the gas cock or valve is in accordance with B.S. 6798 & B.S. 6891. This must be AT LEAST 17mb ! (LPG - 37mb)

3. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working.

‘On’ will be displayed briefly, followed by ‘304’

Fig. 41

Fig. 40

Inlet Gas Pressure Test Point

Gas Type Label

N.G. Factory

Set

When reset for

L.P.G.

Changing the Gas Type

1. It may be necessary to adjust the boiler gas type if the supply is changed, for example when Natural Gas is provided to a rural area previously reliant on Propane. In these instances a replacement Gas Type Label may be required, which is available on request as a spare part.

2. Press & and hold for at least 6 seconds. will be displayed, alternating with .

Measure the Gas Rate

4. With any other appliances & pilot lights turned OFF the gas rate can be measured. It should be:-

4.23 m

Natural Gas 24 model 2.54 m

28 model 2.96 m 33 model 3.49 m

40 model

Propane 24 model 1.92 kg/h

28 model 2.25 kg/h 33 model 2.64 kg/h 40 model 3.2 kg/h

5. Press & together and hold for at least 6 seconds to exit the function.

6. Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the boiler and installation. These details will be required in the event of any warranty work. The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded.

7. For IE, it is necessary to complete a “Declaration of Conformity” to indicate compliance with I.S. 813. An example of this is given in I.S. 813 “Domestic Gas Installations”. This is in addition to the Benchmark Commissioning Checklist.

3. Press to select the next parameter . Press .

4. Press or to select the value that corresponds with the required gas type. For Natural Gas:-

For Propane:-

5. Press to save the change, then to return to the normal display.

Page 31

Case Front Panel

Facia Panel

11.0 Completion & System Draining

11.1 Completion

1. Replace the case front panel, and secure with the screws previously removed.

2. This publication must be handed to the user for safe keeping and each subsequent regular service visit recorded.

3. Set the central heating and hot water temperatures to the requirements of the user. Instruct the user in the operation of the boiler and system.

4. Instruct the user in the operation of the boiler controls. Hand over the User’s Operating, Installation and Servicing Instructions, giving advice on the necessity of regular servicing.

5. Demonstrate to the user the action required if a gas leak occurs or is suspected. Show them how to turn off the gas supply at the meter control, and advise them not to operate electric light or power switched, and to ventilate the property.

Fig. 42

To change the information displayed

The button can be pressed so that the display shows the following

information:-

1 press - ‘00’ alternates with Sub-Code (only when fault on boiler) or ‘000’

2 presses - ‘01’ alternates with CH Temperature

3 presses - ‘02’ alternates with Outside Temperature (where Sensor fitted)

4 presses - ‘03’ alternates with DHW Temperature

5 presses - ‘04’ alternates with DHW Temperature

6 presses - ‘05’ alternates with System Water Pressure

7 presses - ‘06’ alternates with Return Temperature

8 presses - ‘04’ alternates with Flue Temperature

9 presses - ‘05’ alternates with Heat Exchanger Temperature

see the table below:-

6. Show the user the location of the system control isolation switch, and demonstrate its operation.

7. Advise the user that they may observe a plume of vapour from the flue terminal, and that it is part of the normal operation of the boiler.

11.2 System Draining

1. If at any time after installation it is necessary to drain the central heating system (e.g. after replacing a radiator) the De-Aeration Function should be activated.

2. On refilling the system ensure that there is no heating or hot water demand, but that there is power to the boiler.

3. Press & together and hold for at least 6 seconds. The ‘De-Aeration’ Function will be activated.

4. The boiler pump will run for up to 10 minutes during which time the diverter valve will switch between heating & hot water. This will purge air from the system. The display will show .

5. Once De-Aeration is complete set the external controls as required by the user.

Page 32

Flue Sampling

Point

Air Sampling

Point

Case Front Panel Securing Screws

Case Front Panel

Fig. 43

12.0 Servicing

12 .1 Performance Safety Check & Annual Servicing

1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person in accordance with B.S. 7967-4.

2. After servicing, complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication.

IMPORTANT: During routine servicing, and after any maintenance or change of part of the combustion circuit, the following must be checked:-

• The integrity of the complete flue system and the flue seals

(check air inlet sample).

• The integrity of the boiler combustion circuit and relevant

seals as described in Section 12.2.

• The operational gas inlet pressure as described in Section

10.2.1 to 10.2.7 and the gas rate as described in 10.2.8.

• The combustion performance as described in ‘Check the

Combustion Performance’ (12.1.4 to 12.1.6 below).

3. Competence to carry out Checking Combustion

Performance

B.S. 6798 ‘Specification for Installation & Maintenance of Gas Fired Boilers not exceeding 70kW’ advises that:-

• The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results.

• The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturers’ requirements.

• Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment, which covers the use of electronic portable combustion gas analysers in accordance with BS 7967, Parts 1 to 4.

Condensate Trap

Gasket

Sump

Condensate Drain Pipe

Fig. 44

Check the Combustion Performance (CO/CO

ratio)

4. Set the boiler to operate at maximum rate as described in Section 14.1.1 to 14.1.6.

5. Remove the plug from the flue sampling point, insert the

analyser probe and obtain the CO/CO

ratio. This must be

less than 0.004.

6. If the combustion reading (CO/CO

ratio) is greater than this, and the integrity of the complete flue system and combustion circuit seals has been verified, and the inlet gas pressure and gas rate are satisfactory either:

• Perform the ‘Annual Servicing - Inspection’ (Section 12.2) &

re-check.

• Perform the Combustion & Calibration functions (Section

14.0) & re-check.

• Replace the gas valve (Section 13.23) & re-check.

12.2 Annual Servicing - Inspection

1. Ensure that the boiler is cool.

2. Ensure that both the gas and electrical supplies to the

boiler are isolated.

3. Remove the screws securing the case front panel. Lift the panel slightly to disengage it from the studs on top of the case (Fig. 43) and hinge down the Control Box.

4. Disconnect the condensate drain pipe and unscrew the sump from the bottom of the condensate trap assembly (Fig. 44). Remove any deposits from the sump and trap. Clean as necessary and replace the sump.

Page 33

Flame Sensing Electrode

Electrode Position

0.5 ±

12.0 Servicing

12.2 Annual Servicing Inspection (Cont)

5. Remove the clip securing the gas feed pipe to the air/gas venturi. Disconnect the pipe. Do not break the joint between the pipe and gas valve unless necessary.

6. Disconnect the electrode leads, noting their position, and

Fig. 45

Spark Ignition Electrode

the fan electrical plugs (Fig. 46).

7. Undo the four nuts retaining the combustion box cover to the heat exchanger.

8. Carefully draw the fan, collector and cover assembly forward (Figs. 46).

Electrode

Leads

Hall Effect

Sensor

Gas Feed Pipe

Fan, Collector and Cover

Assembly

Fig. 46

Securing Clip

9. Clean any debris from the heat exchanger and check that the gaps between the tubes are clear.

10. Inspect the burner, electrodes position and insulation, cleaning or replacing if necessary. Clean any dirt or dust from the air box.

11. Carefully examine all seals & gaskets, replacing as necessary. Look for any evidence of leaks or corrosion, and if found determine & rectify the cause.

12. Reassemble in reverse order, ensuring the front case panel is securely fitted.

DHW Filter & Turbine Assy. (Fig. 48)

13. If the flow of domestic hot water is diminished, it may be necessary to clean the filter.

14. Turn the DHW isolation cock (Fig. 47) off and draw off from a hot tap.

15. Remove the retaining clip and extract the filter cartridge and rinse thoroughly in clean water. Reassemble and check the flow. Ensure that the turbine spins freely.

Hydraulic Inlet

Assembly

Fig. 48

Restrictor

(not on 40 models)

Filter

Control Box removed for clarity

View underneath appliance

DHW Isolation

Cock

16. Recommission the boiler as described in Section 10.0.

17. Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user.

Fig. 47

Page 34

13.0 Changing Components

Spark Ignition

Electrode

Leads

Fig. 49

Flame Sensing

Electrode

Control Box removed for clarity

IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed recommission the boiler as described in Section 10.0. Always examine any seals or gaskets, replacing where necessary. The Case Front Panel MUST seal effectively against the air box side panels.

See Section 12.1 “Annual Servicing” for removal of case panel, door etc.

13.1 Spark Ignition and Flame Sensing Electrodes

(Fig. 49)

1. Disconnect the electrode leads, noting their positions.

2. Remove the retaining screws securing each of the electrodes to the combustion box cover and remove the electrodes.

3. Check the condition of the sealing gaskets and replace if necessary. Reassemble in reverse order.

4. After changing the Flame Sensing Electrode check the combustion - see Section 14.1.

5. When satisfactory combustion readings are not obtained ensure the electrode position is correct and perform the combustion check again.

Air/Gas

Collector

Cover

Gasket

Gas Feed Pipe

Fan

Fig. 50

Air/Gas Venturi

13.2 Fan (Fig. 50)

1. Remove the clip securing the gas feed pipe to the air/gas venturi. Disconnect the pipe.

2. Undo the screws securing the air/gas collector to the cover (33/40) or extension piece (24/28) and disconnect the fan electrical plugs.

3. Remove the collector and fan assembly, being careful to retain the gasket.

4. Undo the screws securing the fan to the collector. Retain the gasket.

5. Undo the screws securing the venturi to the fan (noting its position) and transfer to the new fan, replacing the seal if necessary.

6. Examine the gasket(s) and replace if necessary.

7. Reassemble in reverse order and perform the Calibration Function - see Section 14.2.

13.3 Air/Gas Venturi (Figs. 50 & 51)

1. Remove the clip securing the gas feed pipe to the venturi.

Fan

Gasket

Fig. 51

Venturi

2. Undo the screws securing the collector to the cover (33/40) or extension piece (24/28) and disconnect the fan electrical plugs.

3. Remove the collector and fan assembly, being careful to retain the gasket.

4. Undo the screws securing the venturi to the fan (noting its position) and fit the new venturi, replacing the seal if necessary.

5. Examine the gasket and replace if necessary.

6. After changing the venturi check the combustion - see Section 14.1.

Page 35

Cover

13.0 Changing Components

Extension Piece

(24 & 28 only)

Gasket

Air/Gas

Collector

Gasket

Burner

Fig. 52

13.4 Burner (Fig. 52)

1. Remove the clip securing the gas feed pipe to the air/gas venturi and disconnect the fan electrical plugs.

2. Undo the screws securing the air/gas collector to the cover (33/40) or extension piece (24/28). Remove this extension piece from the cover (on 24 and 28 models).

3. Withdraw the burner from the cover and replace with the new one.

4. Examine the gasket(s), replacing if necessary.

5. After changing the burner check the combustion - see Section 14.1.

13.5 Insulation (Fig. 53)

1. Remove the clip securing the gas feed pipe to the air/gas venturi and disconnect the fan electrical plugs.

2. Remove the electrodes as described in section 13.1.

Air/Gas

Collector

Spark Ignition

Electrode

Control Box removed for clarity

Heat

Exchanger

Rear

Insulation

3. Undo the nuts holding the cover to the heat exchanger. Draw the air/gas collector, fan and cover assembly away.

4. Remove the cover insulation piece.

5. Fit the new insulation carefully over the burner and align it with the slots for the electrodes.

6. If the rear insulation requires replacement, remove it and all debris from the heat exchanger. Also it may be necessary to separately remove the spring clip from the pin in the centre of the heat exchanger and the ‘L’ shaped clips embedded in the insulation.

7. Do not remove the shrink-wrapped coating from the replacement rear insulation. Keep the insulation vertical and press firmly into position.

8. Examine the cover seal and replace if necessary. Reassemble in reverse order.

Electrode

Leads

Flame Sensing

Electrode

Seal

Cover

Insulation

Fig. 53

Page 36

13.0 Changing Components

Electrical

Plug

Fig. 54

Heating Flow Sensor

Flue Sensor

13.6 Flue Sensor (Fig. 54)

1. Ease the retaining tab on the sensor away and disconnect the electrical plug.

2. Turn the sensor 90° anticlockwise to remove - it is a bayonet connection.

3. Reassemble in reverse order.

13.7 Heating Flow & Return Sensors (Fig. 55)

1. There is one sensor on the flow (red wires) and one sensor on the return (blue wires).

2. After noting the position prise the sensor clip off the pipe and disconnect the plug.

3. Connect the plug to the new sensor and ease the clip onto the pipe as close to the heat exchanger as possible.

13.8 Safety Thermostat (Fig. 55)

1. Pull the terminals off the safety thermostat.

2. Remove the screws securing the thermostat to the mounting plate on the flow pipe.

Safety Thermostat

Fig. 55

Retaining Clip

Plug

Hydraulic Pressure

Sensor

DHW NTC Sensor

Control Box removed for clarity

Pump, Gas Valve

Assemblies and Pipework

removed for clarity

3. Reassemble in reverse order, ensuring that the terminals are pushed fully on.

13.9 DHW NTC Sensor (Fig. 56)

1. Turn off the mains cold water supply tap and draw off the residual domestic hot water.

2. Ease the retaining tab on the sensor away and disconnect the electrical plug.

3. Unscrew the sensor from the hydraulic outlet assembly. Examine the sealing washer, replacing if necessary.

4. Reassemble in reverse order. The plug will only fit one way.

13.10 Hydraulic Pressure Sensor (Fig. 56)

1. Close the flow and return isolation taps and drain the primary circuit.

2. Disconnect the plug from the sensor.

3. Prise off the spring clip and remove the sensor. Examine the ‘O’ ring, replacing if necessary.

4. Reassemble in reverse order.

Fig. 56

Page 37

13.0 Changing Components

13.11 Pump - Head Only (Fig. 57)

1. Disconnect the electrical supply plug from the pump.

2. Close the flow and return isolation taps and drain the primary circuit. Remove the socket head screws securing the pump head to the body and draw the head away.

3. Reassemble in reverse order.

Electrical Supply

Plug

Socket Headed

Screw

Pump Head

Fig. 57

Automatic Air

Vent

Pump Body

Pump Flow

Pipe

Control Box removed for clarity

13.12 Pump - Complete (Fig. 58)

1. Disconnect the electrical supply plug from the pump.

2. Close the flow and return isolation taps and drain the primary circuit. Undo the two screws securing the body to the inlet assembly and pump flow pipe. Draw the complete pump forwards.

3. Pull off the securing clip and remove the automatic air vent. Transfer them to the new pump body.

4. Examine the ‘O’ ring seals, replacing if necessary and reassemble in reverse order.

13.13 Automatic Air Vent (Fig. 58)

1. Close the flow and return isolation taps and drain the primary circuit. Disconnect the gas pipe from the venturi

2. The automatic air vent is a bayonet fitting. Remove by twisting anticlockwise.

3. Fit the new automatic air vent, ensuring the ‘O’ ring is fitted and the cap is open . Reassemble in reverse order.

Fig. 58

Page 38

Control Box removed for clarity

13.0 Changing Components

13.14 Hall Effect Sensor (Fig. 59)

1. Ease the sensor upwards off the hydraulic inlet manifold assembly.

2. Disconnect the electrical plug from the sensor.

3. Connect the plug to the new sensor. Carefully fit the new sensor to the hydraulic assembly, ensuring it is fully down.

13.15 Safety Pressure Relief Valve (Fig. 60)

1. Close the flow and return isolation taps and drain the primary circuit.

2. Disconnect the discharge pipework from the valve. Remove the sealing grommet.

3. Slacken the grub screw securing the pressure relief valve and remove from the inlet assembly.

Hall Effect

Sensor

Hydraulic Inlet

Assembly

Fig. 59

Heating

Pressure

Gauge

Fig. 61

4. On reassembly ensure that the ‘O’ ring is in place and the sealing grommet is correctly refitted to maintain the integrity of the case seal.

13.16 Heating Pressure Gauge (Figs. 61 & 61a)

1. Close the flow and return isolation taps and drain the primary circuit.

2. Remove the gauge from the boiler lower panel.

3. Remove the clip securing the pressure gauge capillary.

4. Fit the new gauge, ensuring that the capillary is routed to prevent any sharp bends. Reassemble in reverse order and ensure the gauge is firmly in position to maintain the integrity of the case seal.

‘O’ ring seal

Fig. 60

Discharge Pipe

Grub Screw

Safety Pressure Relief Valve

Fig. 61a

Pressure Gauge Capillary

Page 39

Plate Heat Exchanger

13.0 Changing Components

13.17 Plate Heat Exchanger (Fig. 62)

1. Close the flow & return isolation taps and the cold mains inlet. Drain the primary circuit and draw off any residual DHW.

2. Remove the gas valve as described in Section 13.20. and disconnect the pressure gauge capillary.

3. Undo the screws securing the plate heat exchanger to the hydraulic inlet & outlet assemblies

4. Withdraw the plate heat exchanger upwards and remove.

Seals

5. There are four rubber seals between the hydraulic assembly and heat exchanger which may need replacement.

Rubber Seal

Diverter Valve

Motor

Multi-pin Plug

Assembly

Valve

Fig. 62

Retaining Clip

Control Box removed for clarity

6. Ease the seals out of the hydraulic assembly. Replace carefully, ensuring that the seal is inserted parallel and pushed fully in.

7. When fitting the new heat exchanger note that the right hand location stud is offset more towards the centre.

8. Reassemble in reverse order.

13.18 Diverter Valve - Motor & Valve Assembly

(Fig. 63)

1. To replace the motor, disconnect the multi-pin plug.

2. Pull off the retaining clip and remove the motor.

3. The motor can now be replaced, or the valve assembly removed.

4. Drain the primary circuit and draw off any hot water once the isolating taps are closed. Disconnect the pressure gauge capillary and h/exchanger flow pipe.

Fig. 63

5. Undo the nuts on the tap rail under the boiler. Remove the screws securing the valve assembly to the boiler bottom panel and plate heat exchanger.

6. Remove the valve assembly. Examine all seals and washers, replacing if necessary. Transfer the DHW NTC and hydraulic pressure sensor to the new valve and reassemble in reverse order.

Page 40

13.0 Changing Components

13.19 P.C.B. & R.D.S. (Removable Data Stick)

(Fig. 64)

NOTE: Both P.C.B. and R.D.S. are available as spare

parts. The P.C.B. is suitable for any boiler model. An R.D.S. specific to the boiler model output & gas type will be required if the R.D.S. from the original P.C.B. is not being transferred. It is recommended that P.C.B. and R.D.S. are replaced together.

1. Ensure that the power to the boiler is isolated and wait 10 seconds.

2. Remove the screws securing the control box cover and release the cover retaining barbs from their slots.

3. Note the position of all plugs and wires on the P.C.B. and disconnect them.

Fig. 64

Slot for Ignition Lead

R.D.S.

4. Undo the securing screws and remove the P.C.B.

IMPORTANT: If only the P.C.B. is being replaced transfer the R.D.S. from the original board to the new one. Where both P.C.B. and R.D.S. are being replaced ensure the new R.D.S. is on new the board.

5. Reassemble in reverse order. Ensure that the ignition lead is connected correctly.

6. P.C.B. ONLY changed - Check the Combustion - see Section 14.1.

7. P.C.B. & R.D.S. changed - enable the Calibration Function as described in Section 14.2, then Check the Combustion see Section 14.1.

Note the correct

orientation of the R.D.S.

Position with the chamfer

as shown.

X24

X20

X22

X36

X37

X23

X13

X10

X11

X12

Page 41

Gas Feed Pipe

Injector

Washer

NOTE: The Injector Washer MUST be fitted as shown between the Valve & Pipe. DO NOT fit the

Injector Washer between the Gas Cock & Valve

13.0 Changing Components

13.20 Gas Valve (Fig. 65)

IMPORTANT: After replacing the valve the CO2must be calibrated as detailed in Section 14.0 Combustion & Calibration. Only change the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see section 12.1.

1. Turn the gas cock off and undo the nut under the boiler. Retain the washer.

Gas Valve

Plug

Washer

Gas Cock

Fig. 65

Lock Nut

Expansion Vessel

Control Box removed for clarity

2. Remove the electrical plug from the valve.

3. Undo the nut on the gas feed pipe and ease the pipe aside. It is recommended that the injector washer is changed as well.

4. Remove the screws securing the gas valve to the boiler bottom panel.

5. Reassemble in reverse order, ensuring the injector washer is in place, and perform the Calibration Function & Combustion Check - see Sections 14.1 & 14.2.

NOTE: Check for gas tightness after replacing gas valve.

13.21 Expansion Vessel (Fig. 66)

1. Close the flow and return isolation taps and drain the primary circuit.

2. Undo the nut on the pipe connection at the bottom of the vessel, and slacken the nut on the hydraulic inlet assembly.

3. Remove the screws securing the support bracket, and withdraw the bracket.

4. Whilst supporting the vessel undo and remove the locknut securing the vessel spigot to the boiler top panel.

Fig. 66

5. Manoeuvre the vessel out of the boiler.

6. Reassemble in reverse order.

Support Bracket

Page 42

14.0 Combustion & Calibration

IMPORTANT: DO NOT insert the Analyser

Probe into the Test Point immediately. This will prevent saturation of the analyser.

During the Calibration Function the combustion ratio may increase for a short time while the boiler performance is optimised.

The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results.

The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturers’ requirements.

Flue Sampling

Point

Plug

14.1 Checking the Combustion

1. Combustion should be:-

Natural Gas 9.0% CO Propane 10.5% CO

at all 3 fan speeds:- ‘100’ (Maximum), the Ignition Phase speed and ‘00’(Minimum).

2. Press & together and hold for at least 6 seconds. the boiler CH output expressed as percentage i.e. be necessary to open one or more hot taps in order to maintain the boiler at full rate.

3. Insert the analyser probe and once stabilised note the CO reading.

4. Press to select the Ignition Phase Speed. A value will be displayed, e.g. ‘33’. Note the CO2reading.

5. Press again to select the Minimum Output. be displayed. Note the CO

6. If the CO any of the speeds, follow the procedure in Section 14.3 opposite to calibrate the boiler.

‘On’ will be displayed briefly, followed by ‘304’ then

is not within the tolerances referred to above at

reading.

± 1.0

± 0.7

‘100’. It may

‘00’ will

Analyser Probe

Fig. 67

14.3 Adjusting the CO

1. Press & together and hold for at least 6 seconds. the boiler CH output expressed as percentage i.e.

2. Press to select the adjustment function. with between ‘-3’ & ‘3’.

3. Decreasing the value lowers the CO value will increase CO

4. Once the correct CO return to the fan speed selection.

5. Using or to select the next fan speed. indicates MINIMUM speed, the other speed (Ignition Phase) will be indicated by, for example boiler model).

6. Repeat step 2. above to adjust the CO Minimum fan speeds. Press & together and hold for at least 6 seconds to exit the function.

‘On’ will be displayed briefly, followed by ‘304’ then

‘304’. Using the & buttons adjust ‘0’

‘0’ will alternate

reading is achieved press to

, and selecting a higher

‘33’ (this varies depending on

.at Ignition Phase and

‘100’.

‘00’

7. To exit the function press & together for 6 seconds.

14.2 Calibration Function

IMPORTANT: Do not commence the Calibration Function

whilst the burner is lit ! The case front panel MUST be fitted.

Note: To obtain an accurate measurement on smaller capacity systems it may be necessary to open one or more hot taps in order to maintain the boiler at full rate.

1. The function is activated by pressing buttons and together for 6 seconds then quickly pressing button

‘On’ is displayed. The Ignition Phase fan speed code will

while then be displayed. Calibration will take approximately 5 minutes.

2. If ‘303’ is displayed, then the Calibration Function has not

been activated correctly. Isolate and reinstate all power sources to the boiler and repeat the above.

3. The boiler will automatically calibrate at

Phase speed then MAXIMUM fan speed (i.e. the boiler has stabilised and self-calibrated at each fan speed the

and symbols will be displayed before the next speed is

automatically set.

4. When self-calibration is complete the boiler will run at

MINIMUM fan speed ( will also be displayed flashing together at regular intervals.

‘00’. These represent the percentage of

‘00’ is MINIMUM fan speed). Once

‘00’ displayed). The following symbols

‘100’, the Ignition

5. To exit the function press .

the calibration function completed.

‘ESC’ will be displayed and

Page 43

Gas

Valve

15.0 Electrical

15.1 Illustrated Wiring Diagram

Low Voltage

External Control

Connection

Terminal Strip

Pump

Fan

Hall Effect

Sensor

Flue Sensor

Safety

Thermostat

b b

From X20 & X31

g/y

b g

X23 X37 X36

X10

X13

X11

g/y

X12

g/y

Connection

g/y

To M2

X22 X20 X24

Hydraulic

Pressure

Switch

Heating

Return Sensor

Heating

Flow

Sensor

DHW

X31

NTC

Sensor

Flame

g/y

Spark

Sensing

Electrode

Ignition

Electrode

Diverter Valve

Motor

Key To Wiring Colours

b - Blue

bk - Black

br - Brown

w - White

gr - Grey

r- Red

g - Green

g/y - Green/Yellow

y - Yellow

Page 44

16.0 Short Parts List

Short Parts List

Key Description Manufacturers No.

A Fan 720768101

B Burner (24/28/33) 720767901

C Spark Ignition Electrode 720767301

D Flame Sensing Electrode 720767101

No. Part No.

Burner (40) 720785201

E Gas Valve 720752301

G Hall Effect Sensor 720788001

I Plate Heat Exchanger (24 & 28) 720852401

Plate Heat Exchanger (33 & 40) 720852601

J Diverter Valve Motor 720788601

K Pump 720787401

M Heating Flow/Return Sensor) 720747101

N DHW NTC Sensor 720789201

O Pump Automatic Air Vent 720787601

P Hydraulic Pressure Sensor 720789001

Q Heating Pressure Gauge 720787201

R Flue Sensor 720851401

S PCB only 720878202

T R.D.S. - 24 720843201

R.D.S. - 28 720843501

R.D.S. - 33 720843801

R.D.S. - 40 720844101

R.D.S. - 24 LPG 720844401

R.D.S. - 28 LPG 720844701

R.D.S. - 33 LPG 720845001

R.D.S. - 40 LPG 720845301

U Injector Washer - 24 (Ø 4.4) 720751701

Injector Washer - 28 (Ø 4.6) 720775801

Injector Washer - 33 (Ø 4.9) 720776001

Injector Washer - 40 (Ø 5.8) 720786601

V Air/Gas Venturi (24 & 28) 720768301

Air/Gas Venturi 33 720785401

Air/Gas Venturi 40 720785601

Page 45

Table Of Error Codes

Gas Valve Connection Cable

Gas Valve Fault

Central Heating NTC Fault

Flue NTC Fault

Central Heating Return NTC Fault

Calibration Required

Pre-circulation Fault

109

Safety Thermostat Operated

110

Primary System Water Pressure Too High

117

Primary System Water Pressure Too Low

118

Circulation Fault (Primary)

125

Flame Failure

128

Flue NTC Operated

130

Interruption Of Gas Supply or Flame Failure

133

Elapsed Time - Gas Valve Open Without Gas

134

Interruption Of Gas Supply (Internal Error)

135

Flow/Return Sensor Temperature Test

154

Fan or Fan Wiring Fault

160

Circulation Fault (Dry Fire)

270

Hot Water NTC Fault

321

False Flame

384

The button can be pressed so that the display shows the following

information:-

1 press - ‘00’ alternates with Sub-Code (only when fault on boiler) or ‘000’

2 presses - ‘01’ alternates with CH Temperature

3 presses - ‘02’ alternates with Outside Temperature (where Sensor fitted)

4 presses - ‘03’ alternates with DHW Temperature

5 presses - ‘04’ alternates with DHW Temperature

6 presses - ‘05’ alternates with System Water Pressure

7 presses - ‘06’ alternates with Return Temperature

8 presses - ‘04’ alternates with Flue Temperature

9 presses - ‘05’ alternates with Heat Exchanger Temperature

17.0 Fault Finding

17.1 Initial Fault Finding Checks

1. Check that gas, water and electrical supplies are available at the boiler.

2. Electrical supply = 230V ~ 50 Hz.

3. The preferred minimum gas pressure is 20mb (NG) 37mb (LPG).

4. Carry out electrical system checks, i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable meter.

NOTE: These checks must be repeated after any servicing or fault finding.

7. Ensure all external controls are calling for heat and check all external and internal fuses. Before any servicing or replacement of parts, ensure the gas and electrical supplies are isolated.

17.2 Error Codes

1. If a fault occurs on the boiler an error code may be shown by the facia display.

2. The codes are a flashing number, either two or three digit, preceded by the symbol :-

followed by

components.

followed by 55 (after replacing R.D.S.) indicates calibration

required (Section 14.2).

20, 28, 40, 160 or 321 indicates possible faulty

‘Service Due’ Message

1. After 11 months operation the ‘Service Due’ message will be shown on the boiler display. (If the installation has been subject to prolonged electrical isolation or power cuts this period may be longer than 11 months)

2. Once the service has been completed satisfactorily the ‘Service Due’ message can be reset or de-activated.

To Reset

4. Press & for 6 seconds. Using scroll through until

5. Press to scroll to press to return the display to normal.

To De-activate

6. Press & for 6 seconds. Using scroll through until

7. Press until Using scroll through to

8. Press until then press to return the display to normal.

‘22’ is displayed. Press .

‘15’. Confirm with then

‘22’ is displayed. Press .

‘22’ is displayed again. Press .

‘50’. Press .

‘25’ is displayed. Confirm with

110 indicates overheat of the primary system water.

117 is displayed when the primary water pressure is greater

than 2.7 bar.

118 is displayed when the primary water pressure is less than

0.5 bar.

133, 134 and 135 indicate that the gas supply has been

interrupted, ignition has failed or the flame has not been detected.

128 is displayed if there has been a flame failure during normal

operation.

125 is displayed in either of two situations:-

i) If between 15 and 30 seconds of the burner lighting the boiler

temperature has not changed by 1°C.

ii) If within 10 minutes of the burner lighting the boiler actual

temperature twice exceeds the selected temperature by 30°.

In these instances poor primary circulation is indicated.

3. By pressing the 'Reset' button for 1 to 3 seconds when 110, 125, 133, 134, 135, 09, 15, 128 & 384 are displayed it

is possible to relight the boiler.

4. If this does not have any effect, or the codes are displayed

regularly further investigation is required.

Page 46

Refer to “Illustrated Wiring Diagram” for position of terminals and components

Central Heating - Follow operational sequence

17.0 Fault Finding

Turn on mains power

The display illuminates

YES

09, 15, 110, 125, 133, 134,

135 or 384 flashing

20, 28, 40 or 321 flashing

117 or 118 flashing

Set Central Heating

temperature to Maximum.

symbol flashing, pump runs

YES

Fan runs after up to 3 minutes

YES

Go to section ‘A’

Press the reset button for 1 to

3 seconds

Go to section ‘D’

Go to section ‘I’

Ensure all controls and

programmers are calling for

heat

160 flashing

Go to section ‘C’

YES

If 09, 15, 110 or 384 is flashing or re-occurs

regularly, check all PCB connections. If this has no

effect replace the PCB.

If 110 is still flashing go to

section ‘H’

Ensure controls are set to

demand and verify the

contacts are closed

Go to section ‘B’

YES

Fan runs at correct speed

Spark at ignition electrodes up to 5 seconds & for 3 attempts

YES

Burner lights

YES

109 flashing

110 flashing

Diverter valve open to Central

Heating circuit

YES

160 flashing

Go to section ‘C’

133 flashing

Go to section ‘E’

Burner goes out after 5

seconds

125 flashing after 1 min

Go to section ‘H’

Go to section ‘K’

YES

Go to section ‘F’. Press the

reset button for 1 to 3 seconds

133 flashing

Go to section ‘G’

Go to section ‘J’

YES

Burner modulates to maintain

set temperature

130 flashing

Burner goes out

YES

Check Heating flow sensor.

Go to section ‘D’

Go to section ‘M’

Fan stops after 10 seconds

YES

Boiler operation correct

Page 47

Domestic Hot Water - Follow operational sequence

17.0 Fault Finding

Turn on mains power

The display illuminates

YES

09, 15, 110, 125, 133, 134,

135 or 384 flashing

20, 28, 40 or 321 flashing

117 or 118 flashing

Set Hot Water temperature to Maximum & fully open hot tap.

symbol flashing, pump runs

YES

Fan runs after up to 3 minutes

YES

Go to section ‘A’

Press the reset button for 1 to

3 seconds

Go to section ‘D’

Go to section ‘I’

DHW flow rate greater than

2litres/min

160 flashing

Go to section ‘C’

YES

If 09, 15, 110 or 384 is flashing or re-occurs

regularly, check all PCB connections. If this has no

If 110 is still flashing go to

section ‘H’

Go to section ‘L’

Burner lights

YES

effect replace the PCB.

Go to section ‘L’

Go to section ‘B’

YES

Fan runs at correct speed

YES

Spark at ignition electrodes up to 5 seconds & for 3 attempts

YES

Burner lights

YES

109 flashing

110 flashing

3 Way Valve open to

Domestic Hot Water circuit

YES

160 flashing

Go to section ‘C’

133 flashing

Go to section ‘E’

Burner goes out after 5

seconds

125 flashing after 1 min

Go to section ‘H’

Go to section ‘K’

YES

Go to section ‘F’. Press the

reset button for 1 to 3 seconds

133 flashing

Go to section ‘G’

Go to section ‘J’

YES

Burner modulates to maintain

set temperature

130 flashing

Burner goes out

YES

Check CH NTC sensor.

Go to section ‘D’

Go to section ‘M’

Fan stops after 10 seconds

YES

Boiler operation correct

Page 48

Fault Finding Solutions Sections

17.0 Fault Finding

Is there 230V at:

Main terminals L and N Check electrical supply

Main terminal fuse Replace fuse

3. PCB - X10 connector

Main terminals L and N

Switch to DHW mode maximum flow and press reset. During next 3 minutes check:-

230V at PCB - X13 connector (between blue & brown - see Wiring Diagram)

Replace PCB

YES

Check wiring

230V between PCB - X13 connector (blue) and PCB - X11 connector (black) - see Wiring Diagram

Replace PCB

YES

Connection

OK at X41

Display

illuminated

230V at pump

Check wiring

YES

Display or

Main PCB fault

Replace pump

Fan connections correct at fan & PCB

X11 and X23 connectors - see

Wiring Diagram.

YES

230V at PCB - X11 connector (between blue & brown - see Wiring Diagram)

Replace PCB

Temperature sensor faulty.

Check correct location and wiring.

YES

Cold resistance approximately 10k @ 25° C (DHW and CH sensors) (resistance reduces with increase in temp.)

YES

Make connections

Fan jammed or

faulty wiring

Replace sensor

YES

Replace fan or wire

Gas at burner

Ensure gas is on and purged

Check wiring and PCB - X36 connector

see Wiring Diagram

Replace PCB

YES

Replace gas valve

Page 49

17.0 Fault Finding

Check and correct if necessary

1. Ignition electrode and lead

2. Electrode connection

3. Spark gap and position

Burner

Flame Sensing Electrode

Electrode Position

1. Check supply pressure at the

gas valve:-

Natural Gas - Minimum 17 mbar

Propane - Minimum 37 mbar

YES

Check wiring - see Diagram

Viewing Window

Spark Ignition Electrode

Replace PCB

0.5 ±

Check and correct if necessary

1. The set of the gas valve (CO2 values - see instruction)

2. Flame sensing electrode and lead connections

3. Flame sensing electrode position

Replace flame sensing electrode or PCB

Safety thermostat operated or

faulty

Check for and correct any

system faults

Allow to cool. Continuity

across thermostat terminals

more than 1.5 ohm

Check Flow & Return Sensors -

see section ‘D’

YES

Replace safety thermostat

Is 110 still flashing ?

YES

Replace PCB

Page 50

17.0 Fault Finding

CH system pressure less than

0.5 bar or greater than 2.7 bar

Ensure that the boiler and system

are fully vented

YES

Check wiring and PCB - X22

connector for approx. 5V DC

between green & black - see

Check flow temperature sensor connections

YES

Wiring Diagram

and position. Cold resistance approximately 10k @ 25° C (CH sensors)

(resistance reduces with increase in temp.)

YES

Restore system pressure

YES

System fault - correct

Go to section ‘B’

Replace hydraulic pressure sensor

Replace PCB

Replace sensor

Is there 230V at:

1. PCB - X13 connector terminals between:-

Blue & Black (central heating mode) Blue & Brown (domestic hot water mode)

see Wiring Diagram

YES

Check diverter valve cable

Diverter valve motor Replace 3-way valve motor

Is mains water filter & assembly

clean, and rotor moving freely ?

Clean or replace

YES

effect sensor - see Wiring Diagram

Replace PCB

Check wiring and PCB - X22

connector for approx. 5V DC

between red & blue from Hall

Replace PCB

YES

Replace Hall Effect Sensor

Temperature sensors faulty. Cold resistance approximately 10k @ 25° C (CH sensor) 20k @ 25° C (Flue sensor) (resistance reduces with increase in temp.)

2. If pump is running the heat exchanger could be

obstructed

YES

Replace sensor

Replace heat exchanger

Page 51

18.0 External Low Voltage Controls

Optional Outdoor Sensor

North

1/2 H

2.5m Min

West

18.1

1. The Sensor must be fixed to an external wall surface of the property it is serving. The wall must face a north or west.

2. The Sensor should be approximately half the height of the living space of the property, and a minimum of 2.5m above ground level.

3. It must be positioned away from any sources of heat or cooling (e.g. flue terminal) to ensure accurate operation. Siting the Sensor above doors and windows, adjacent to vents and close to eaves should be avoided.

18.2

1. Ensure the electrical supply to the boiler is isolated. Undo the securing screws and lift the case front panel off.

2. Disengage the securing tab and hinge the control box downwards. Undo the terminal block cover securing screw and remove the cover.

3. Remove one of the grommets, pierce the diaphragm and insert the wires from the Outdoor Sensor.

Positioning the Optional Outdoor Sensor

NOTE: DO NOT position it on a south facing wall in direct

sunlight !

Connecting the Optional Outdoor Sensor

Boiler Flow

Temperature

Outdoor Temperature

4. Leave sufficient slack in the wires to allow the Control Box to be hinged fully open. Refit the grommet.

5. Connect the wires from the Outdoor Sensor to positions 4 & 5 on M2 as shown. Refit the cover.

18.3

1. Ensure that there is power to the boiler.

2. The Central Heating temperature buttons & are used to select the desired curve as shown on the graph.

3. Normally the display will show the current temperature of the water in the boiler (e.g. 41°C). As the buttons are pressed the curve identification code the will be shown, from

‘90’

4. To select the most appropriate curve consideration must be given to the expected outdoor temperature range. This must then be compared to a boiler flow temperature that will satisfy the needs of the user, e.g. If outdoor temperatures in the range 0°C to -5°C are anticipated and a boiler flow of no more than 60°C required, select Curve

5. As a further example, if Curve temperature of 5°C the boiler flow temperature will be just below 70°C. In the event of the outside temperature falling to 0°C, the boiler flow will increase to 80°C.

Setting the Sensor Curve

‘20’

is selected, at an outside

‘40’

‘00’

6. Continue with the installation and commissioning of the boiler as described in the Installation & Servicing Instructions.

7. Explain to the user how to select a different temperature curve.

Page 52

18.0 External Low Voltage Controls

1. Press Securing Tab

2. Ease away from Backplate

IMPORTANT !

Optional 7 Day Wired Sensor

18.4 Connecting the Optional 7 Day Wired Sensor

NOTE: The yellow link wire between terminals 1 & 2 on terminal block M1 MUST be removed when fitting the 7 Day Wired Sensor.

1. Ensure that the power to the boiler is isolated.

2. Remove the backplate from the unit by pressing down on the rear tab and easing apart.

3. Locate the sensor and use wiring as described in the literature supplied with it.

4. Pass the wiring through the slots in the backplate and connect as shown opposite to 2 & 3 on the sensor backplate and 1 & 2 of boiler terminal M2.

5. Complete fitting as described in the sensor literature, turn the power back on and set the controls to the requirements of the user.

Programmer & Room

Sensor Backplate

IMPORTANT ! When fitting Low Voltage Controls remove the Ye llow Link Wire from the Boiler Terminal Block M1

1 23

Boiler Wiring

Terminal M2 Low Voltage Terminal

Block

Boiler Mains Voltage Terminal Block M1

Page 53

1. Press Securing Tab.

IMPORTANT !

2. Ease Backplate away.

18.0 External Low Voltage Controls

Optional 7 Day Wireless Sensor &

24hr Wireless Sensor

18.5 Connecting the Optional 7 Day Wireless Sensor

& 24hr Wireless Sensor (kit includes a Sensor &

Receiver - the Receiver is wired into the boiler).

NOTE: The yellow link wire between terminals 1 & 2 on terminal block M1 MUST be removed when fitting the 7 Day Wireless Sensor & 24hr Wireless Sensor.

1. Ensure that the power to the boiler is isolated.

2. Remove the backplate from the receiver unit by pressing down on the rear tab and easing apart.

3. Locate the receiver and use wiring as described in the literature supplied with it.

4. Pass the wiring through the slots in the backplate and connect as shown opposite to the OT connection on the receiver backplate and 1 & 2 of boiler terminal M2.

IMPORTANT ! When fitting Low Voltage Controls remove the Ye llow Link Wire from the Boiler Terminal Block M1

Boiler Wiring Terminal M2 Low Voltage Terminal

Block

Boiler Mains Voltage Terminal Block M1

5. Complete fitting as described in the sensor/receiver literature, turn the power back on and set the controls to the requirements of the user.

Page 54

*All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance

will then be issued to the customer.

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

Customer name: Telephone number:

Address:

Boiler make and model:

Boiler serial number:

Commissioned by (PRINT NAME): Gas Safe register number:

Company name: Telephone number:

Company address:

Commissioning date:

CONTROLS (tick the appropriate boxes)

Time and temperature control to heating

Room thermostat and programmer/timer Programmable room thermostat

Load/weather compensation Optimum start control

Time and temperature control to hot water Cylinder thermostat and programmer/timer Combination Boiler

Heating zone valves Fitted Not required

Hot water zone valves Fitted Not required

Thermostatic radiator valves Fitted Not required

Automatic bypass to system Fitted Not required

Boiler interlock Provided

ALL SYSTEMS

’s instructions Yes

What system cleaner was used?

What inhibitor was used? Quantity litres

Yes N o

CENTRAL HEATING MODE measure and record:

Gas rate m³/hr OR ft³/hr

Burner operating pressure (if applicable) mbar OR Gas inlet pressure mbar

°C

Central heating return temperature °C

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)? Yes N o

Yes N o

DOMESTIC HOT WATER MODE Measure and Record:

Gas rate m³/hr OR ft³/hr

Burner operating pressure (at maximum rate) mbar OR Gas inlet pressure at maximum rate mbar

Cold water inlet temperature °C

Hot water has been checked at all outlets Yes Temperature °C

I/min

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes

ALL INSTALLATIONS

Record the following:

At max. rate: CO ppm AND CO/CO

Ratio

At min. rate: (where possible) CO ppm AND CO/CO

Ratio

The heating and hot water system complies with the appropriate Building Regulations Yes

The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions Yes

The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

Commissioning Engineer’s Signature

Customer’s Signature

www.centralheating.co.uk

Page 55

www.centralheating.co.uk

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

SERVICE RECORD

SERVICE 01

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 02

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 03

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 04

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 05

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 06

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 07

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 08

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 09

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 10

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

*All installations in England and Wales must be

to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance

will then be issued to the customer.

Page 56

All descriptions and illustrations provided in this leaflet have been

carefully prepared but we reserve the right to make changes and

improvements in our products which may affect the accuracy of the

information contained in this leaflet. All goods are sold subject to our

standard Conditions of Sale which are available on request.

BAXI

A Trading Division of Baxi Heating UK Ltd (3879156)

Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 0844 871 1525 Technical Enquiries 0844 871 1555 Website www.baxi.co.uk e&oe

Comp No. 7206334 - 09 (9/14)

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