Baxi Neta-tec Combi GA Quick Start Manual

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Page 1

Installation & Servicing Instructions

Neta-tec 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 Neta-tec Combi 24 GA

47-075-51

G.C.N

Baxi Neta-tec Combi 28 GA

G.C.No 47-075-52

Baxi Neta-tec Combi 33 GA

G.C.No47-075-53

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:

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

Full acknowledgement of author and source must be given.

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.

0086

The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations.

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 declare that no substances harmful to health are contained in the appliance or used during appliance manufacture.

The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force, and only used in a suitably ventilated location.

In GB, the installation must be carried out by a 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 & System Draining 30

12.0 Servicing 31

13.0 Changing Components 33

14.0 Combustion & Calibration 42

15.0 Electrical 43

16.0 Short Parts List 44

17.0 Fault Finding & ‘Service Due’ 45

18.0 Optional Outdoor Sensor s 51

Benchmark Checklist 54

Page 7

Information Label

1.0 Introduction

1.1 Description

1. The Baxi Neta-tec Combi GA Range are fully automatic gas fired wall mounted condensing combination boilers. They are 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)

3. The boiler is factory set for use on Natural Gas (G20). It can be adapted 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 control box. 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 / domestic 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.

1.3 Contents of Pack

Gas Type Label

Fig. 2

The pack contains:-

• Boiler

• Wall Plate (including taps)

• Template

• Fittings & Literature Pack

Data Badge

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. Boiler Adaptor

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. Exp. Vessel Locating Stud

9. Flame Sensing Electrode

10. Air/Gas Collector

11. Spark Ignition Electrode

12. Combustion Box Cover & Burner

13. Control Box Display

14. Condensate Trap

15. Safety Pressure Relief Valve

16. Gas Valve

17. Diverter Valve Motor

18. Boiler Control

19. Optional Timer

20. Boiler Drain Tap

21. Heating Flow Sensor

22. Safety Thermostat

Page 9

Boiler Schematic Layout

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 the 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 Domestic Hot Water Sensor (‘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. Diverter Valve Assembly

3. Diverter Valve motor

4. CH System Pressure Gauge

5. Central Heating Filter

6. Domestic Hot Water Filter

7. Domestic Hot Water Priority Sensor (‘Hall Effect Sensor’)

8. Domestic Hot Water NTC sensor

9. Non-return Valve

10. Hydraulic Pressure Sensor

11. Boiler Drain Tap

12. Pressure Relief Valve

13. Plate Heat Exchanger

14. Condensate Trap

15. Gas Valve

16. Safety Thermostat (105°C)

17. Heating Flow Sensor

18. Flue Sensor

19. Boiler Adaptor

20. Primary Heat Exchanger

21. Spark Ignition Electrode

22. Burner

23. Flame Sensing Electrode

24. Air/Gas Collector

25. Return Heating Sensor

26. Fan

27. Air/Gas Venturi

28. Expansion Vessel

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

3.3 Boiler Frost Protection Mode

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.

Page 10

4.0 Technical Data

4.1

Appliance Type C

Appliance Category CAT II

13 C33 C43 C53

2H 3P

Heat Input CH (Net) Max Min 24 model kW 20 3.5 28 model kW 24 3.9 33 model kW 28 4.8

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

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

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

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

Injector

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

NATURAL GAS ONLY !

Max Gas Rate (Natural Gas - G20)

(After 10 mins)

24 model m 28 model m 33 model m

/h 2.54

/h 2.96

/h 3.49

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

Inlet Pressure (Propane - G31)

mbar 37

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 133

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 - 700mm Overall Height Inc Flue Elbow - 860mm Casing Width - 390mm Casing Depth - 300mm

Clearances

Above Casing 175mm Min Below Casing 150mm Min* Front 450mm Min (For Servicing) Front 5mm Min (In Operation) L.H. Side 5mm Min R.H. Side 5mm Min :

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

Weights

(24 model)

Packaged Boiler Carton 38.5kg Installation Lift Weight 34 kg

(28 model)

Packaged Boiler Carton 38.5kg Installation Lift Weight 34 kg

(33 model)

Packaged Boiler Carton 40.5kg Installation Lift Weight 36kg

NOxClass 5

N.G. 9.0% ± 0.7 L.P.G. 10.5% ± 1.0

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)

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

DHW Flow Rate @ 35o C Rise 9.8 11.5 13.5

Min Working DHW Flow Rate 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)

litre litre

Max Capacity of CH System 100 100

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)

SEDBUK Declaration

SAP 2005 Seasonal Efficiency for N. G.

models is 91.1%

SAP 2005 Seasonal Efficiency for L.P.G.

Pump

Available Head See graph below

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.

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

5.5

4.5

3.5

2.5

Metre (wg)

1.5

0.5

35°C to 60°C max (± 5°C) dependent upon flow rate

Pump - Available Head

200 400 600 800 1000 1200

Flow Rate (l/h)

Page 11

Dimensions

5.0 Dimensions and Fixings

At least 1.5°

A 700mm

B 300mm*

*This can be reduced to 290mm by removing the boiler control access flap

C 390mm

D 116mm Ø Min.

E 160mm

(207mm for 80/125mm flue systems)

360° Orientation

F 130mm

G 106mm

H 228mm

J 162mm

Boiler Side

Condensate

Drain

40 mm

Flue Ø 100mm

Tap Rail

Pressure

Relief Valve

(15mm)

65 mm 65 mm 65 mm 65 mm 65 mm

162,5 mm

Heating

Flow

(22mm)

Hot Water

Outlet

(15mm)

Gas Inlet

(22mm)

Cold Water

Inlet

(15mm)

Heating

Return

(22mm)

Boiler Side

Page 12

6.0 System Details

6.1 Information

1. The Baxi Neta-tec Combi 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 are 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

CH Return

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 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

Fig. 6

Filling Loop Connections

Control Box removed for clarity

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). 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.

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).

Pressure Relief Valve

Discharge Pipe

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 Neta-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

390mm

5mm Min

175mm Min

(300mm Min if

using 80/125mm

flueing system)

700mm

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.

300mm

(290mm 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).

7.5 Electrical Supply

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

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 by using the available flue deflector.

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)

2. All fittings should be fully engaged. The approximate

(i)

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

(ii)

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.

Page 21

315mm 500mm

Fig. 14

Flue Deflector

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)

For details of Plume Displacement Kit lengths see the Flue Installation Guide supplied in the literature pack.

Fig. 15

Fig. 16

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)

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. If a proprietary guard is used it must be identified as suitable for use with condensing boilers

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

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

8.5 Flue Deflector (Fig. 16)

1. If required, push the flue deflector over the terminal end and rotate to the optimum angle for deflecting plume. 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

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.

130mm

For Side Flue Exit

Fig. 18

Fig. 17

175 mm Minimum Clearance

Ø 8 mm

Profile of Outercase

5 mm Minimum Side Clearance

50 m m

Vertical Flue Centre Line

Boiler Mounting Bracket Fixing Slots

View from Underneath

Part No. 720636502

116mm Dia Minimum

Aperture For Flue Tube

Side Flue

Centre Line

228 mm

5 mm Minimum Side Clearance

Ø 8 mm

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.

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.

3/4” BSP

Connections

Heating Flow

Fig. 20

Flushing Tube

Heating Return

Condensate

Pressure

Drain

Relief Valve

(15mm)

40 m m

65 m m 65 mm 65 mm 65 mm 65 mm

Part No. 720636502

162.5 m m

Heating

Flow

(22mm)

Hot Water

Outlet

(15mm)

Combi Only Not System

(22mm)

Gas Inlet

Cold Water

Inlet

(15mm)

Combi Only Not System

Recommended

Heating

Return

(22mm)

Fig. 19

200 mm

150 mm Minimum Clearance

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. Make the flow and return connections to the isolation taps. Flush the system thoroughly to remove all impurities (see System Details, Section 6.2).

Page 23

Boiler Mounting

Bracket

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.

Sealing Washers

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.

4. 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 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

Discharge Pipe

Condensate Trap Outlet 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 inadvertantly 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. 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 40mm 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 40mm. 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

Boiler Elbow

9.0 Installation

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

Ensure Elbow is fully engaged into Boiler Adaptor

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

Ensure Flue is fully engaged into Elbow

Adaptor

Fig. 29

9.6 Fitting the Flue (Cont)

10. Remove the flue elbow and insert the flue through the hole in the wall. Fit the flue trims if required, and refit the elbow to the boiler adaptor, ensuring that it is pushed fully in (Fig. 29).

11. 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).

12. 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).

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

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

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

Fig. 30

Slots at bottom

Fig. 31

Page 26

Control Box

9.0 Installation

9.7 Making The Electrical Connections

1. See Section 7.5 for details of the electrical supply. 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).

Room ‘Stat

230V

g/y

IMPORTANT: Any thermostat MUST be suitable for 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 connected to terminal 1. (Figs. 35 & 36). If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Figs. 35 & 36.

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

Frost Thermostat

Room ‘Stat

230V

Pipe Thermostat

8. Replace the terminal block cover.

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

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

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

g/y

2. These should be performed using a suitable meter, and

9.8 Preliminary Electrical Checks

include checks for Earth Continuity, Resistance to Earth, Short Circuit and Polarity.

Page 27

11.0 Commissioning

bar

10.0 Commissioning

10.1 Commissioning the Boiler

Fig. 37

Automatic Air

Pump

Fig. 38

Cap

Vent

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 paragraph 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

Control Box removed for clarity

Heating

Pressure Gauge

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 pressure will be displayed. followed by . However

be displayed.

if is shown, press for 2 to 4 seconds . will now

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

Fig. 39

Display showing Gas

Type Recognition

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 minutes to check the gas type (N.G. or Propane L.P.G.). The boiler software checks the combustion value against the set value.

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

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).

ratio will increase for a short time while the gas type is established.

13. IMPORTANT: In cases where the supplied gas is Propane gas will be displayed. Press for at least 6 seconds to

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 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 & .

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 !

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.

Proceed to put the boiler into operation as follows:

Page 28

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 Commissioning

10.2 Checking the Combustion - ‘Chimney Sweep’

Function (cont)

1. This procedure is mandatory in GB from April 2014. It is strongly recommended to perform the procedure before that date.

Set Boiler to Minimum Rate

Allow the combustion to

2 ratio

Yes

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 29

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

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

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.

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.

Measure the Gas Rate

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

Natural Gas 24 model 2.54 m

28 model 2.96 m 33 model 3.49 m

Propane 24 model 1.92 kg/h

28 model 2.25 kg/h 33 model 2.64 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.

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

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 30

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 Flow 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 CH Return Temperature

8 presses - ‘07’ alternates with Flue Temperature

9 presses - ‘08’ 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 31

Flue Sampling

Point

Air Sampling

Point

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

10.3.1 to 10.3.7 and the gas rate as described in 10.3.4.

• The combustion performance as described in ‘Check the Combustion Performance’ (12.1.4 to 12.1.6 below).

Case Front Panel Securing Screws

Condensate Trap

Case Front Panel

Fig. 43

Control Box removed for clarity

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.

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.

Condensate Drain Pipe

Gasket

Sump

Fig. 44

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.

Baxi Neta-tec Combi GA Quick Start Manual

Specifications and Main Features

Frequently Asked Questions

User Manual