Baxi Platinum Combi 24 HE A, Platinum Combi 28 HE A, Platinum Combi 33 HE A, Platinum Combi 40 HE A Installation & Servicing Instructions Manual

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Page 1

Platinum Combi HE A Range

Gas Fired Wall Mounted Condensing

Combination Boiler

Installation & Servicing Instructions

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

Page 2

Natural Gas

Baxi Platinum Combi 24 HE A

G.C.No47 075 31

Baxi Platinum Combi 28 HE A

G.C.No47 075 32

Baxi Platinum Combi 33 HE A

G.C.No47 075 33

Baxi Platinum Combi 40 HE A

G.C.No47 075 34

© 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 Ltd, 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.

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.

0086

ISO 9001

FM 00866

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. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly. Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1 January 2006.

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.

Page 3

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact a government approved

inspector

LABC will record the data

and will issue a

certificate of compliance

‘Gas Safe Register’ will issue a

Building Regulations Compliance

Certificate to the property owner

and inform the relevant LABC

You must ensure that the

certificate number issued by

the ‘Gas Safe Register’ is written

onto the Benchmark Checklist

Scheme Members only

Call ‘Gas Safe Register’ on:

0800 408 5577

or log onto:

www.gassaferegister.co.uk

within 10 days

If you notify via the ‘Gas Safe

the Building Regulations

certificate on members’ behalf

Complete the

Benchmark Checklist

Install and Commission this appliance to manufacturer's

instructions

Competent Person's

Self Certification Scheme

Building Control

Complete the

Benchmark Checklist

Install and Commission this appliance to manufacturer's

instructions

Page 4

Legislation

Codes of Practice - refer to the most recent version

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

In GB the following Codes of Practice apply: Standard Scope

BS 6891 Gas Installation. BS 5546 Installation of hot water supplies for domestic

purposes. BS EN 12828 Heating systems in buildings. 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 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.

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 Bodies 0085 & 0086.

For GB/IE only.

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.

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

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

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 Plume Displacement 25

10.0 Installation 29

11.0 Commissioning 34

12.0 Completion 38

13.0 Servicing 39

14.0 Changing Components 41

15.0 Combustion Check 49

16.0 Electrical 50

17.0 Short Parts List 51

18.0 Fault Finding 52

Benchmark Checklist 58

Section Page

Page 7

1.0 Introduction

1.1 Description

1. The Baxi Platinum Combi HE A is a fully automatic gas fired wall mounted condensing combination boiler. 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 kW CH (Condensing)

28 models - 28 kW DHW

25.9 kW CH (Condensing)

33 models - 33 kW DHW

30.3 kW CH (Condensing)

40 models - 40 kW DHW

34.4 kW CH (Condensing)

3. It is designed for use on Natural Gas (G20).

4. The boiler is supplied with a filling loop and integral timer.

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

6. 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. 1).

7. The boiler model name and serial number are also shown on the information label on the underside of the facia. This is for user reference.

8. The boiler is intended to be installed in residential / domestic environments on a governed meter supply only.

9. The boiler must be installed with one of the purpose designed flues such as the standard horizontal telescopic flue kit, part no. 5118069 .

10. All systems must be thoroughly flushed and treated with

inhibitor (see section 6.2).

Important: If the boiler is installed at a high point in the

system it is strongly recommended that Automatic Air Vent Kit 720004701 is fitted.

1.2 Contents of Pack

The pack contains:-

• Boiler

• Wall Plate (including taps)

• Set of Pipe Connections

• Template & ‘Quick Fit’ Guide

• Literature Pack

• Filling Loop

Fig. 1

Control Box

Case Front Panel

Data Badge

Information Label

Page 8

2.0 General Layout

2.1 Layout

1. Expansion Vessel

2. Automatic Air Vent

3. DHW Plate Heat Exchanger

4. Circulation Pump

5. Drain Off Point

6. Pressure Relief Valve

7. Selector Switch

8. Central Heating System Pressure Gauge

9. PCB

10. Control Box

11. 3-Way Valve Assembly

12. Condensate Trap

13. Flame Sensing Electrode

14. Spark Electrode

15. Primary Heat Exchanger

16. Fan Assembly

17. On/Off/Reset Selector Switch

18. Central Heating Temperature Control

19. Hot Water Temperature Control

20. Venturi

21. Air/Gas Collector

22. Combustion Box Cover & Burner

23. Igniter

24. Burner On Light

25. Central Heating Mode Light

26. Domestic Hot Water Mode Light

27. Display

28. Position of Integral Timer

bar

GRASSLIN

Page 9

3.0 Appliance Operation

3.1 Central Heating Mode (Fig. 2)

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 (Fig. 3)

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.

IMPORTANT: When the selector switch is in the ‘0’ (Off) position the electrical supply to the boiler is isolated. The boiler will not operate and the integral timer will require resetting once the selector switch is set to either Position (i) or Position (ii).

3.3 Frost Protection Mode

1. The frost protection mode is integral to the appliance and functions only with the selector switch (see Section 2.1) in the domestic hot water and central heating position. If the system temperature falls below 5° C then the boiler will fire on its minimum setting until a flow temperature of 30° C is reached. Further protection can be incorporated by using a system frost thermostat.

3.4 Pump Protection

1. With the selector switch (see Section 2.1) in either the central heating or central heating and domestic hot water position, the pump will automatically operate for 1 minute in every 24 hours to prevent sticking.

5 6

1213141516

1 Primary Heat Exchanger 2 Burner 3 Ignition Electrode 4 Flame Sensing Electrode 5 Gas Valve 6Pump 7 Automatic Air Vent 8 Plate Heat Exchanger/Automatic By-pass 9 Flow Sensor with Filter & Regulator 10 Pressure Relief Valve 11 Boiler Drain Point 12 Heating Return 13 Cold Water Inlet On/Off Valve and Filter 14 Gas Inlet

15 Domestic Hot Water Outlet 16 Heating Flow 17 Pressure Gauge 18 Water Pressure Sensor 20 Fan 21 Diverter Valve Assembly 22 Diverter Valve Motor 23 Domestic Hot Water Flow Temperature Sensor 24 Safety Thermostat 25 Central Heating Temperature Sensor 26 Expansion Vessel

Key

Central Heating Circuit

Domestic Hot Water Circuit

Fig. 3

5 6

1213141516

Fig. 2

Page 10

4.0 Technical Data

200 400 600 800 1000 1200

0.5

1.5

2.5

3.5

Metre (wg)

Flow Rate (l/h)

Pump - Available Head

5.5

4.5

4.1 Platinum Combi 24, 28, 33 & 40 HE A

Flue Terminal Diameter 100mm Dimensions Projection 125mm

Outercase Dimensions

Casing Height - 780mm Overall Height Inc Flue Elbow - 965mm Casing Width - 450mm Casing Depth - 345mm

Weights

(24 model)

Packaged Boiler Carton 48.6 kg Installation Lift Weight 43.6 kg

(28 model)

Packaged Boiler Carton 49.2 kg Installation Lift Weight 44.2 kg

(33 & 40 model)

Packaged Boiler Carton 50kg Installation Lift Weight 45kg

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 @ 30

C Rise 11.43 13.3 15.7 19.1

DHW Flow Rate @ 35

C Rise 9.8 11.5 13.5 16.4

Min Working DHW Flow Rate 2 2 2 2

Pump

Available Head See graph below

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

Connections copper tails Gas Supply - 22mm Central Heating Flow - 22mm Central Heating Return - 22mm Cold Water Mains Inlet - 15mm DHW Flow - 15mm Pressure Relief Discharge - 15mm

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

NOxClass 5

Clearances Above Casing 200 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

(In Operation)

This is the MINIMUM recommended dimension. A greater clearance will aid installation and maintenance.

Heat Input CH (Net) Max Min 24 model kW 20.5 7 28 model kW 24.7 9 33 model kW 28.9 9.7 40 model kW 32.8 9.9

Heat Output CH (Non-Condensing)

Max Min 24 model kW 20 6.8 28 model kW 24 8.7 33 model kW 28 9.4 40 model kW 32 9.6

Electrical Supply 230V~ 50H

(Appliance must be connected to an earthed supply)

Power Consumption

155W (24, 28) 160W(33 & 40)

Electrical Protection

IPX0D (with timer) IPX5D (without timer)

Internal Fuse Rating F2L

Appliance Category CAT I

Inlet Pressure (Natural Gas - G20)

mbar 20

Injector (Natural Gas - G20)

7.5mm (24 & 28) 12mm (33 & 40)

Appliance Type C

Heat Output CH (Condensing)

Max Min 24 model kW 21 7.4 28 model kW 25.9 9.5 33 model kW 30.3 10.2 40 model kW 34.4 12.1

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

Max Gas Rate (Natural Gas - G20)

(After 10 mins) 24 model m3/h 2.61 28 model m3/h 3.1 33 model m3/h 3.6 40 model m3/h 4.36

Condensate Drain

To accept 21.5mm (

/4in) plastic waste pipe

Heat Input CH (Gross) Max Min 24 model kW 22.7 7.8 28 model kW 27.4 10 33 model kW 32.1 10.8 40 model kW 36.4 11

Heat Input DHW (Gross) Max 24 model kW 27.4 28 model kW 32.1 33 model kW 37.7 40 model kW 45.7

External Fuse Rating 3A

SAP 2005 Seasonal Efficiency for all models

is 91.1%

This value is used in the UK Government’s Standard

Assessment Procedure (SAP 2005) for energy rating

of dwellings. The test data from which it has been

calculated has been certified by 0087.

SEDBUK (2005) Declaration

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.

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

Page 11

5.0 Dimensions and Fixings

Dimensions

A 780mm

B 345mm

C 450mm

D 116mm Ø Min.

E 185mm

(207mm for 80/125mm flue systems)

F 145mm

G 131mm

H 180mm

J 270mm

Domestic Hot

Water Outlet

(15mm)

Cold Water

Inlet

(15mm)

Heating

Return

(22mm)

Heating

Flow

(22mm)

Pressure Relief

Valve

(15mm)

Gas

Inlet

(22mm)

65 mm

65 mm 65 mm

65 mm

32.5 mm

Condensate

Drain

Tap Rail

360° Orientation

Tube Ø 100mm

At least 1.5°

Page 12

6.0 System Details

6.1 Information

1. The Baxi Platinum Combi HE A 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 Central Heating Circuit

1. The appliance is suitable for fully pumped SEALED SYSTEMS ONLY.

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 utilises the primary side of the DHW plate heat exchanger as an automatic integral bypass.

6.4 System Control

1. Further external controls (e.g. room thermostat) should be fitted to optimise the economical operation of the boiler.

Page 13

6.0 System Details

6.5 System Filling and Pressurising

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.

A filling loop & instructions are provided with the boiler

2. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment.

3. 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”.

4. 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.

IMPORTANT: If the boiler is installed at a high point in the system it is strongly recommended that Automatic Air Vent Kit 720004701 is fitted.

6.6 Expansion Vessel (Central Heating only)

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. 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.

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).

Fig. 4

Fig. 6

Stop Valve

Double Check Valve

DHW Mains Inlet

CH Return

Temporary Loop

Safety Pressure Relief Valve

Discharge Pipe

Stop Valve

Filling Loop Connections

Fig. 5

Page 14

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”.

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.

Boiler

Other Tap Outlets

Expansion Vessel*

To Hot Taps

Check Valve*

Pressure Reducer Valve*

Stop Tap

Fig. 7

* See 6.8 for instances when these items may be required

Page 15

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. If the boiler is sited in an unheated enclosure then it is recommended to leave the ON/OFF Selector Switch in the domestic hot water and central heating position to give frost protection.

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.

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).

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

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.

150mm Min*

780mm

450mm

200mm Min

(300mm Min if

using 80/125mm

flueing system)

5mm Min

450mm Min

For Servicing

Purposes

Fig. 8

Fig. 9

In Operation

5mm Min

At least 1.5°

Page 16

7.0 Site Requirement

7.3 Ventilation of Compartments

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

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

7.4 Gas Supply

1. The gas installation should be in accordance with the relevant standards. In GB this is BS 6891. 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

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 and NOT FITTED with any optional integral timer or thermostat, 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.

Fig. 10

Gas Service Cock

Zone 2

Zone 1

Zone 0

Zone 2

Window Recess

0.6 m

Ceiling

Outside Zones

Zone 2

Zone 1

Zone 0

2.25 m

Window Recess Zone 2

0.6 m

Fig. A

Fig. B

In GB Only

Page 17

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 (

/4in) plastic 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.

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.

21.5mm

2.5° Minimum fall

i) Termination to an internal soil and

vent pipe

450mm min*

Boiler

2.5° Minimum fall

ii) External termination via internal discharge branch

e.g sink waste - downstream*

Sink

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

50mm per metre of pipe run

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

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.

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

32mm

Insulation

Page 18

7.0 Site Requirements

7.7 Condensate Drain (cont.)

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.

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.

Boiler

2.5° Minimum fall

iii) Termination to a drain or gully

Boiler

500mm min

2.5° Minimum fall

iv) Termination to a purpose made soakaway

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

50mm per metre of pipe run

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

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

Boiler

vi) pumped into an external soil & vent pipe

2.5° Minimum fall

50mm per metre of pipe run

Condensate Pump

Unheated Location (e.g. Garage)

Basement or similar (heated)

Boiler

v) pumped into an internal discharge branch

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

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

2.5° Minimum fall

50mm per metre of pipe run

Condensate Pump

Sink

Basement or similar (heated)

Boiler

2.5° Minimum fall

50mm per metre of pipe run

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

The ‘Trace Heating’ element must be installed in accordance with the instructions supplied. External runs & those in unheated locations still require insulation.

vii) to a drain or gully with extended

external run & trace heating

Page 19

7.0 Site Requirements

J,K

D E

Likely flue positions requiring a flue terminal guard

J,K

Fig. 12

Fig. 11

300 min

Terminal Assembly

Top View Rear Flue

Property Boundar y Line

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

Opening Window or Door

150mm MIN.

IMPORTANT: If fitting a Plume Displacement Flue Kit, the air inlet must be a minimum of 150mm from any opening windows or doors (see Section 9.0).

Plume Displacement Kit

Air Inlet

Fig. 12a

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.

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.

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 E2Below eaves. 25 F2Below balconies or car port roof. 25 G2From a vertical drain pipe or soil pipe. 25 H2From an internal or external corner. 25 I

Above ground, roof or balcony level. 300

From a surface or boundary line facing a terminal. 600

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

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 B.S.5440-1.

Page 20

8.0 Flue Options

8.1 Horizontal Flue Systems

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

2. All fittings should be fully engaged. The approximate engagement is 40mm. Apply soap solution 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

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: All flue systems must be securely supported at least once every metre. Suitable pipe supports are available as accessories.

Horizontal Flues

(ii)

(i)

Plume Displacement Kit 60 /100 dia 1M Extensions 45° & 93° elbows are also available - see Section 9.0

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.

(ii)

(i)

This bend is equivalent to 1 metre

Total equivalent length =

A+B+C+2x90°Bends

This bend is equivalent to 1 metre

Page 21

8.0 Flue Options

Vertical Flues

Vertical Flues (Twin Pipe)

(i)

(ii)

8.2 Twin & Vertical Flue Systems

1. Maximum permissible equivalent flue lengths are:-

(60/100) (80/125) Vertical Concentric 10 metres 20 metres Vertical Twin Pipe 15 metres

2. 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

Twin Flue Pipe

135° bend 0.25 metres

91.5° bend 0.50 metres

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.

The total equivalent

length for this example is

= 6.5 metres.

1m extension

135°bend

91.5°bend

0.25m

0.5m

5 2 2

5.0m

0.5m

1.0m

AIR DUCT

fittings/pipes

Sub total

Equivalent

Length Value

Equivalent Length Air Duct = 6.5m

1m extension

135°bend

91.5°bend

0.25m

0.5m

5 2 2

5.0m

0.5m

1.0m

FLUE DUCT

fittings/pipes

Sub total

Equivalent

Length Value

Equivalent Length Flue Duct = 6.5m

(ii)

(i)

Roof

Terminal

This bend is equivalent to 1 metre

Total Equivalent Length = A+B+C+1x90°Bend

All vertical and angled runs must be included, measured from the boiler adaptor (i) to the joint with the flue terminal (ii). One 91.5° bend or two 135° bends can be included without reduction of the flue length.

If further elbows are required the flue length must be reduced by the following amounts:-

1 metre for each 91.5° bend

0.5 metre for each 135° bend

1m Min to

15m Max

120mm Min apart

1m Min

15m Max

600mm Min apart

Mini Terminal on Air Duct (sited in loft)

IMPORTANT: All flue systems must be securely

supported at least once every metre. Suitable pipe supports are available as accessories.

Page 22

8.0 Flue Options

K,K1

U,W

8.3 Flue Accessories

Key Accessory Size Code No

FLUE GROUP A Concentric Flue System 100mm diameter

A3 Telescopic Internal Flue Kit 315-500mm 5119654 A2 Telescopic Flue (incl elbow) 5118069 A Horizontal Flue Terminal (incl elbow) 5118489 B Flue Extension 1000mm 5111074 C Flue Bend 93° 5111075 D Flue Bend (pair) 135° 5111085 U Pipe Support (painted) 100mm Ø 5111080 R Vertical Flue Adaptor 5111070 P Wall Liner 5111067 S Flue Terminal Deflector 5111068

FLUE GROUP N Twin Flue System 80mm diameter

E Flue Extension (pair) 1000mm 5111087 F Flue Bend (pair) 90° 5111072 G Flue Bend (2 pair) 135° 5111086 J Vertical Flue Boiler Adaptor Kit 720089801 H Vertical Flue Adaptor 5111084 W Pipe Support (pair) 80mm 5111081 Y Flue Termination Kit

(horizontal termination) 80mm 5120172 Z Single Terminal 80mm 5121791 Q Adaptor 60/80 5121792 T Pitched Roof Terminal 25°/45° 5106164

FLUE GROUP G Flue System 80/125mm diameter

A4 Horizontal Flue Kit 5118580 B Straight Extension Kit 1000mm 5118584 D Bend Kit (pair) 135° 5118597 C Bend 91.5° 5118588

FLUE GROUP A, N, G Vertical Flue Kits

K Vertical Flue Terminal

(use with 5111070) 5111078

K1 Vertical Flue Terminal 5118576 L Pitch Roof Flashing 25°/50° 5122151 M Roof Cover Plate 246143 N Flat Roof Flashing 246144

Y,Z

Page 23

8.0 Flue Options

8.4 Twin Flue Duct Adaptor

1. The kit allows connection of a twin flue system to the boiler adaptor.

8.5 Twin Flue Connection

1. Engage the twin flue duct adaptor in the boiler adaptor, making sure that it is pushed down as far as possible.

2. Ensure that the air & flue ducts are connected correctly and that they are adequately supported (at least once every metre using the available pipe supports).

3. Ensure that all joints and elbows are fully engaged and cannot become disconnected during operation.

Flue Duct Connection

Boiler Adaptor

Air Duct Connection

Page 24

8.0 Flue Options

8.6 For Roof Terminals

1. In the case of a pitched roof 25 - 50 degrees, position the lead tile to replace/flash over existing roof tiling. Make an aperture in the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained. The adjustable plastic collar can either be positioned on the lead tile or the lower tube of the roof terminal prior to the final positioning of the vertical flue through the tile. Check the collar is correctly located to suit required roof pitch (either 25° to 38° or 37° to 50°). From inside the roof adjust the flue to a vertical position and secure to the roof structure with the clamp supplied.

2. For flat roof installations the aluminium flashing must be incorporated into the roof covering and the appropriate aperture made in the roof decking. The vertical flue is lowered onto the flashing making sure the collar of the flue locates securely with the flashing. (A mastic seal may be necessary). From inside the roof, adjust the flue to a vertical position and secure to the roof structure with the clamp supplied.

IMPORTANT: If the boiler is not fitted immediately after the flue system, temporary precautions must be taken to prevent rain entry into the room of installation. Any precautionary measures must be removed prior to commissioning the boiler.

8.7 Flue Dimensions

The standard horizontal telescopic flue kit allows for lengths between 315mm and 500mm from elbow to terminal (Fig. 13).

The maximum permissible equivalent flue length is:

10 metres (60/100 system) 20 metres (80/125 system)

8.8 Flue Trim

1. The rubber flue trim supplied may be fitted to either the outside wall or on the inner wall of installation.

8.9 Terminal Guard (Fig. 14)

1. When codes of practice dictate the use of terminal guards, they can be obtained from most Plumbers’ and Builders’ Merchants.

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.

8.10 Flue Deflector

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.

Fig. 13

Fig. 14

315mm 500mm

Push Fit Adaptor

Air Duct

Flue Duct

Cut the same amount off the Air Duct & Flue Duct

Approx

1425mm

Flue Deflector

Page 25

9.0 Plume Displacement

9.1 Plume Displacement Kit (Fig. 14b)

Kit No 5118638

Content of kit

1 0.9m 60/100 Concentric Flue 1 1m 60 Dia Exhaust Flue Pipe 1 Adaptor 2 60 Dia Support Brackets 1 93° Elbow/Plume Outlet Assembly 1 Flexible Flue Trim 3 “O” Rings 1 ‘Jubilee Clip 1 Elbow

1. This kit is recommended for installations where the condensate plume emitted from the flue may cause a nuisance or affect the surroundings.

2. The terminal must be positioned outside the building with the air inlet facing downward and outlet connection upwards.

3. The plume outlet must always be at least 45° to the wall, with the ‘peak’ uppermost to prevent rain entry (Figs. 15 &

16), and be at least 2 metres above ground level. It must be secured as shown in Fig. 12a. The plume outlet must also be at least 500mm from the air inlet in any direction (Fig. 16).

NOTE: The outlet must be positioned so that any condensate plume is directed away from adjacent surfaces. There must be a constant fall along the entire length of the flue system from the outlet back to the boiler.

4. It is possible to reduce or increase (with the addition of extensions) the length of either or both the 60/100 concentric and 60Ø exhaust.

5. Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly.

6. The minimum length of the concentric flue is 100mm when measured from the edge of the flue elbow.

IMPORTANT: The maximum equivalent length of concentric flue is:- 8 metres Additional bends may be fitted in the concentric flue, but the equivalent length must be reduced by 1 metre (93° elbow) or 0.5 metres (45° elbow).

7. 60Ø 1 metre extensions (including support bracket), and additional 93° & 45° elbows are available. Any additional 93° & 45° elbows must be accounted for when calculating flue lengths.

NOTE: Permitted positions of the plume outlet relative to doors, windows etc. are the same as for conventional concentric flues as detailed in the main Installation & Servicing Instructions and BS5440 Pt. 1. It is NOT necessary to fit a terminal guard over the air inlet or the plume outlet.

Air Inlet at Bottom

‘Peak’ Uppermost

Fig. 15

Fig. 16

500mm Min.

45°

Outlet must be at least 45° from wall face

93° Elbow/Plume Outlet Assembly

60Ø Exhaust Flue Pipe

60Ø Support Bracket

Flexible Flue Trim

60/100Ø Concentric Flue

Adaptor

O Ring

‘Jubilee’ Clip

0.9 metres

Fig. 14b

Fig. 14a

Elbow

Page 26

9.0 Plume Displacement

Concentric 60/100 Flue

60Ø Exhaust

Fig. 17

60 Ø Exhaust (metres) X

Concentric 60/100 Flue (metres) Y

34 65798

28/33/40

Fig. 18

60 Ø Exhaust (metres) X

Concentric 60/100 Flue (metres) Y

34 65798

28/33/40

60 Ø Exhaust (metres) X

Concentric 60/100 Flue (metres) Y

34 65798

28/33/40

Flue Length - Worked Example Baxi Platinum Combi 28 HE

In Fig. 18 opposite an additional 93° elbow and pair of 45° elbows have been included in the 60Ø exhaust. Also 3 straight extension pieces have been used.

To calculate total length:Length of 60Ø supplied in kit = 1 metre 3 x 1 metre Extensions = 3 metres 1 x 93° Elbow = 1 metre 2 x 45° Elbow = 1 metre (0.5 metres each)

Total 60Ø = 6 metres

After consulting the table in Example 3 it can be determined that the concentric flue could be up to approximately 2.3 metres long.

Concentric Flue

Support Bracket

45° Elbow

93° Elbow

1 metre Extension

1 metre supplied in kit

Additional Accessories

93° Elbow 5121369 45° Elbow (Pair) 5121370 1 metre 60Ø Extension 5121368

9.2 Determining Permissible Lengths

In the graph the solid line diagonal represents the relationship between the concentric flue assembly (and any extensions) and the 60Ø exhaust (and any extensions or additional bends).

Example 1 - Not Permissible

If, for instance, a concentric length of 5 metres was required and the 60Ø exhaust needed to be 6 metres the graph shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line.

Example 2 - Flue Lengths OK

Where both lengths have been determined they can be applied to the graph to check that the installation is permissible. For example, if it was known that 2 metres of concentric flue and 4 metres of 60Ø exhaust were required, the values could be applied to the graph as shown in Example 2. As the point of intersection of the dotted lines is below the solid diagonal line, the combination of lengths is shown to be acceptable.

Example 3 - Flue Lengths OK

In the example shown, assume that the concentric part of the flue needs to be 2.3 metres long. Find the position of ‘2.3’ on the horizontal axis of the graph and then project upwards to the solid diagonal line. This is represented by the vertical thick dotted line. Where this dotted line intersects with the solid diagonal line on the graph, project across to the vertical axis. As can be seen this corresponds with 6 metres. Therefore, the total equivalent length of the 60Ø exhaust can be up to 6 metres. Any elbow equivalencies must be accounted for i.e. 93° elbows are equal to 1 metre, each 45° elbow to 0.5 metres.

Example 1 Flue Lengths - Not Permissible

Example 2 Flue Lengths - OK

Example 3 Flue Lengths - OK

Page 27

9.0 Plume Displacement

Min. 2 metres

Fig. 19

Fig. 24

30mm

Fig. 21

Fig. 23

Fig. 22

Adaptor

9.3 General Fitting Notes

1. Cut a hole in the external wall which the concentric flue assembly will pass through. The hole should allow the flue to fall back to the boiler at an angle of at least1.5°.

2. When completed the terminal must be at least 2 metres above ground level (Fig. 19).

3. Measure and cut to size the concentric assembly and any extensions that are being used.

4. Insert the concentric assembly through the hole from outside the building.

5. If required, the flexible flue trim should be fitted prior to this as it cannot be fitted after. Use the large ‘Jubilee’ clip to secure the trim to the flue (See Fig. 20, trim shown dotted), with the screw part of the clip at the bottom.

6. Connect any extensions or elbows that are being used to the concentric assembly. Engage the extension, elbow or concentric assembly in the boiler flue elbow. Fit the boiler flue elbow to the boiler adaptor.

7. Ensure that the concentric assembly and any extensions fall back to the boiler at an angle of at least 1.5° and that the external air inlet is to the bottom.

8. Use suitable brackets to support the concentric assembly and any extensions, and make good inside and outside.

9. The 60Ø exhaust can now be fitted. Slide the adaptor over the plain end of the 60Ø exhaust (Fig. 22) and engage the exhaust in the terminal. Slide the adaptor down over the spigot. Mark and drill the adaptor, using a 2mm bit, as shown in Fig. 21. Secure the adaptor to the spigot using one of the screws supplied.

10. If it is necessary to shorten the 60Ø exhaust or any of the extensions, the excess material must be cut from the plain end of the pipe.

11. Determine the position of the 60Ø exhaust and mark on the wall a suitable position for the support bracket. If extensions are being used, a support bracket is supplied in each kit.

12. Drill the wall, and fit the bracket(s) using the plug and screw provided.

13. Mark and drill the 60Ø exhaust, using a 2mm bit, as shown in Fig. 23. Complete the installation of the 60Ø exhaust, securing in the brackets.

14. Fit the 93° elbow/plume outlet and secure with the two remaining screws supplied. Ensure the plume outlet is at least 45° to the wall and that the ‘peak’ is uppermost (Fig. 24).

50mm

Flue Trim

Position of ‘Jubilee’ Clip screw

Fig. 20

Spigot

Page 28

9.0 Plume Displacement

9.3 General Fitting Notes (cont.)

15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air.

16. It is also possible to separate the plume outlet from the 93° elbow to allow the flue to be installed as shown in Fig. 25.

17. To do this, first slacken the two screws retaining the plume outlet to the elbow, and remove the outlet (Fig. 26). The elbow can now be used to connect the vertical to horizontal 60Ø exhaust (Fig. 25). Retighten the screws in the elbow.

18. The outlet can now be fitted into the female end of an 60Ø extension piece. It must be secured using two of the screws supplied in the bag with the ‘Jubilee’ clip.

19. Mark the female end of the extension at 30mm as shown in two positions, directly opposite each other (Fig. 27).

20. Using a suitable bit (e.g. 2mm), drill through the extension and outlet. Secure using two of the screws supplied.

21. The remaining screw must be used to secure the adaptor to the concentric terminal.

22. When the plume outlet is positioned under a balcony or other projection (Fig. 28) it must protrude at least 200mm (it is not necessary to extend it further than this).

23. When under balconies or projections it is permissible to rotate the concentric flue length up to 70°, clockwise or anti-clockwise (Fig. 29), if there is insufficient space to connect vertically.

24.This will allow the connection of the exhaust to the outlet spigot.

25. All other minimum & maximum dimensions must be adhered to, and the air inlet positioned such that it will not be subject to rain entry.

500mm Min.

200mm Min.

30mm

Fig. 26

Fig. 27

Fig. 25

Fig. 28

Plume Outlet

Elbow

70°

Fig. 29

Outlet Spigot

Concentric Flue Length (shown end-on)

Page 29

10.0 Installation

10.1 Unpacking & Initial Preparation

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.

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 (Figs. 30 & 31).

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. It is preferable to use the vertical fixing slots.

4. Mark the position of the centre of the flue hole (rear exit). For side flue exit, mark as shown (Fig. 32).

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.

IMPORTANT: ONLY on 40 models the Cold Water Inlet tap is fitted with a flow regulator. The copper tail is factory fitted on this model, but must be loosened and turned through 180° to point downwards. Ensure the joint is fully tight (Fig. 34).

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

10.2 Flushing

1. Connect a tube to the central heating flow or return pipe (Fig. 33).

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

Fig. 33

145mm

For Side Flue Exit

Central Heating Return

Flushing Tube

Wall Plate

Fig. 32

Flow Regulator

40 model only

Fig. 34

Fig. 30

Fig. 31

Page 30

Fig. 38

Pressure Relief Valve

Discharge Pipe

Fig. 35

10.0 Installation

10.3 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 slots at the top rear of the boiler on the wall plate (Fig. 37a) (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.

10.4 Fitting the Pressure Relief Discharge Pipe

(Figs. 37 & 38)

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.

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 (Fig. 37).

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

IMPORTANT: Make all soldered joints before connecting to the pressure relief valve.

10.5 Condensate Drain (see section 7.7)

1. Connect the condensate drain to the trap outlet pipe.

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”.

2. The connection 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.

Fig. 36

Fig. 37

Suggested Lifting Points shown as shaded area

Remove Sealing Caps from under the Boiler after lifting into position

Sealing Washers

Page 31

10.0 Installation

10.6 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. The outer duct of the Connection Assembly is painted white. On the Terminal Assembly the outer duct is unpainted.

2. The two sections can be adjusted to provide a length between 315mm and 500mm (Fig. 39) 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. 41).

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. 40).

5. If the distance from the flue elbow to the outside face of the wall (‘X’ in Fig. 40) 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. 40) 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’.

Wall Thickness

(X)

Wall Thickness

(X)

Flue Elbow

Fig. 39

Fig. 41

Adaptor

Apply Lubricant for ease of assembly.

Ensure Elbow is fully engaged into Boiler Adaptor

315mm 500mm

Terminal Assembly

Connection Assembly

Fig. 40

Page 32

10.0 Installation

10.6 Fitting the Flue (Cont)

8. Adjust the two telescopic sections to dimension ‘Y’ (Fig. 42). Ensure that the rivets and holes in the Connection Assembly are aligned horizontally (Fig. 43).

9. Using a 2mm bit, drill through the holes at the end of the Connection Assembly into the Terminal Assembly and secure them together using the screws supplied (Fig. 42). Seal the joint with the tape provided (Fig. 44).

10. Remove the flue elbow and insert the flue through the hole in the wall. Refit the elbow to the boiler adaptor, ensuring that it is pushed fully in (Fig. 41).

11. Draw the flue back through the wall and engage it in the elbow. It may be necessary to use soap solution or similar to ease assembly of the elbow adaptor and flue (Fig. 44).

12. Ensure that the terminal is positioned with the slots to the bottom (Fig. 45).

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.

14. Fit the flue trim if required, and if necessary fit a terminal guard (see Section 8.8 & 8.9).

CONCENTRIC VERTICAL FLUE

15. Once the length of the vertical concentric extension has been determined mark and carefully cut off the excess material. The cut end MUST be square and free of burrs to ensure correct insertion into the boiler adaptor.

16. Measure 25mm from the end of the flue extension and apply a length of tape around the outer duct (Fig. 46).

17. Engage the extension into the adaptor up to this position (Fig. 47). Once the installation of the flue is complete and all support brackets are securely in place remove the tape.

Slots at bottom

Fig. 43

Fig. 44

Fig. 45

Apply Lubricant for ease of assembly.

Ensure Flue is fully engaged into Flue Elbow

Sealing Tape

‘Peak’ to be uppermost

Rivet & Hole to be

aligned on horizontal

centreline

Dimension ‘Y’

Securing Screw

Fig. 42

Adaptor

Apply Lubricant for ease of assembly.

Ensure Extension is fully engaged into Boiler Adaptor

25mm

Extension

Cut End

Fig. 46

Tape

Fig. 47

Page 33

10.0 Installation

10.7 Making The Electrical Connections

The boiler is fitted with a 1.3m length of 3 core cable. This can be connected to the fused 3A 230V 50H

Z supply.

NOTE: Both the Live and Neutral connections are fused.

To connect an external control proceed as follows:-

1. Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel.

2. Completely undo the screws securing the facia panel and hinge it down (Fig. 48).

3. Undo the terminal block cover securing screw and remove the cover (Fig. 48).

4. Slacken the unused cable clamp on the LH side of the boiler chassis (Fig. 49). Insert the external control wiring through the clamp and route it to the terminal block.

5. Refer to the instructions supplied with the control.

IMPORTANT: The room thermostat MUST be suitable for 230V switching.

NOTE: An external frost thermostat cannot be used

with the optional integral timer.

6. 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. (Fig. 50). If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Fig. 50.

7. Ensure that the external control input cable(s) have sufficient slack to allow the control box to drop down. Tighten the cable clamp on the boiler chassis.

8. Replace the terminal block cover, routing the external control input cable(s) through the second cut-out.

10.9 Preliminary Electrical Checks

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.

g/y

Room ‘Stat

Fused Spur

230V

Fig. 49

Fig. 50

Fig. 48

Cable Clamp

Terminal Block Cover

Facia Panel

g/y

Frost Thermostat

External Clock

Room ‘Stat

Fused Spur

230V

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.

Page 34

11.0 Commissioning

Pump

Automatic Air

Vent

Pressure Gauge

Screw

bar

Fig. 52

Selector Switch

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

bar

GRASSLIN

Pump

Fig. 54

Fig. 53

Display

11.1 Commissioning the Boiler

1. Reference should be made to BS:EN 12828 & 14336 when commissioning the boiler.

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

3. Open the mains water supply to the boiler.

4. Open all hot water taps to purge the DHW system.

5. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler.

6. Open the screw on the automatic air vent on the pump body (Fig. 52).

IMPORTANT: If the boiler is installed at a high point in the system it is strongly recommended that Automatic Air Vent Kit 720004701 is fitted. Ensure that this vent is open.

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

8. Pressurise the system to 1.5 bar then close and disconnect the filling loop.

9. Turn the gas supply on and purge according to in GB BS 6891 and in IE I.S. 813 “Domestic Gas Installations”.

10. Test for gas tightness.

11. Hinge the facia panel upwards and refit the case front panel. Tighten the securing screws.

12. 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:

13. The Combustion Check procedure as shown by the chart

in 11.2 is mandatory from April 2014. The method of setting the boiler to operate at maximum and minimum rates to comply with the procedure is described below.

14. Ensure that all external controls are calling for heat. The actual current boiler temperature is shown on the display.

15. Turn both control knobs fully anticlockwise, then quickly turn the right hand knob 1/4 clockwise twice and back fully anticlockwise.

16. The display will now alternate between ‘SF’ and the current boiler temperature and both green LEDs will flash.

17. To set to maximum rate. Turn the left hand knob fully clockwise. As the knob is turned the display will change, indicating the fan speed.

18. The display will show ‘00’, indicating maximum rate, then revert to ‘P ‘ alternating with the current boiler temperature.

19. To set to minimum rate. Turn the left hand knob fully anti-clockwise. As the knob is turned the display will change, indicating the fan speed. When the display reads ‘ 0’ the boiler runs at minimum rate.

20. This function is maintained for 20 minutes unless the maximum CH temperature is exceeded. The function can be disabled at any time by turning the right hand knob.

Page 35

11.0 Commissioning

Set Boiler to Maximum Rate

(see 11.1.13) 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% ?

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.

Check CO & Combustion Ratio at Maximum Rate

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

Is CO < 350ppm and CO/CO

2 ratio

< 0.004 ?

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

2 ratio <

0.004 ?

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.

Set Boiler to Minimum Rate

(see 11.1.19) Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser.

Yes

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.

Yes

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.

11.2 Checking Combustion

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

Page 36

11.0 Commissioning

11.3 Setting the Timer

The Electro-Mechanical Timer allows the central heating system to be set every 15 minutes.

Using the three position switch the timer will allow either constant operation, timed operation or central heating off.

Move the switch button by sliding to the desired position.

Three position switch (Fig. 54a)

Constant (Top position): The heating will be on

constantly irrespective of the position of the tappets.The heating will be controlled by the main thermostat on the appliance and/or any external controls.

Timed (Central position): The heating will operate according to the position of the tappets and be controlled as above.

0 Off (Bottom position): No central heating.

Domestic hot water will operate on demand.

To set the time of day

Turn the timer outer bezel clockwise, to align the pointer with the correct time to the nearest 15 minutes ensuring that A.M./P.M. is considered. Do not at any time

attempt to turn the bezel anti-clockwise.

To set the timed heating program

Decide which times of the day the central heating is required.

The heating will operate when the white tappets are set to the outer edge of the bezel.

To ensure the heating stays OFF set the required tappets inwards towards the centre of the bezel.

Each tappet represents 15 minutes.

For example: If the heating is not required between 10 A.M. and 11 A.M. the four tappets anticlockwise from the 10 A.M. will be set inwards (Fig. 54b).

Constant

Time Pointer

Timed

Off

Rotate to adjust time

Off Position

On Position

Time Pointer

Fig. 54a

Fig. 54b

Page 37

11.0 Commissioning

Selector Switch

Display

bar

GRASSLIN

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Fig. 56

Fig. 57

Fig. 58

Fig. 59

Fig. 60

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Fig. 55

x 2

11.4 Check the Operational (Working) Gas Inlet

Pressure

1. Ensure that all controls are calling for heat, and the selector switch is in the central heating and hot water position ( ). The current boiler temperature is shown on the display.

2. To check the gas rate it is necessary to set the boiler to ‘Calibration Mode’.

3. Turn both temperature control knobs fully anticlockwise, then quickly turn the DHW temperature knob

/4clockwise

twice and back fully anticlockwise (Fig. 55).

4. The display will now alternate between ‘SF’ and the current boiler temperature and both green LEDs will flash (Figs. 56 &

57).

5. Turn CH temperature control knob fully clockwise. As the knob is turned the display will change from ‘0’ to ‘00’ (Fig. 58) indicating maximum rate, then revert to ‘P’ alternating with the current boiler temperature (Figs 59 & 60).

6. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point (Fig. 55a) is in accordance with B.S. 6798 & B.S. 6891.

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

Measure the Gas Rate

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

24 model 2.61 m

28 model 3.1 m

33 model 3.6 m

40 model 4.36 m

9. The ‘Calibration Function’ is active for 20 minutes unless the maximum CH temperature is exceeded.

10. The function can be disabled at any time by turning the DHW temperature knob.

11. 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.

12. 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.

Fig. 55s

Gas Valve

Gas Pressure

Test Point

Page 38

12.0 Completion

12.1 Completion

1. Instruct the user in the operation of the boiler and system including the integral timer, explaining the operational sequence.

2. Set the central heating and hot water temperature control knobs to the requirements of the user.

3. Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance 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.

4. 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.

5. Hand over the Users Operating, Installation and Servicing Instructions giving advice on the necessity of regular servicing.

Fig. 61

Facia Panel

Case Front Panel

Page 39

13.0 Servicing

Case Front Panel

Fig. 62

Facia Panel Securing

Screws

Fig. 63

Inner Door

Panel

Fig. 64

Condensate

Trap

Sump

13 .1 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.

• The integrity of the boiler combustion circuit and relevant seals as described in Section 13.2.

• The operational gas inlet pressure as described in Section

11.3.1 to 11.3.7 and the gas rate as described in 11.4.8.

• The combustion performance as described in ‘Check the

Combustion Performance’ (13.1.4 to 13.1.6 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.

Check the Combustion Performance (CO/CO

ratio)

4. Set the boiler to operate at maximum rate as described in Section 15.1.1 to 15.1.6.

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 13.2) &

re-check

• Adjust the gas valve (Section 15.0) & re-check

• Replace the gas valve (Section 14.23) & re-check

13.2 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. Slacken the screws securing the facia panel. Lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel, allowing the facia to hinge down (Fig. 62).

4. Remove the screws securing the inner door panel. Lift the panel slightly to disengage it from the studs on top of the case (Fig. 63).

5. Unscrew the sump from the bottom of the condensate trap assembly (Fig. 64) and remove any deposits from the sump and trap. Clean as necessary and replace the sump.

Page 40

13.0 Servicing

Fig. 66

Cold Water

Inlet Tap

Blanking

Cap

Threaded

Bush

Fig. 67

Fig. 65

Hall Effect

Sensor

Hydraulic Inlet

Assembly

Fig. 68

Gas Inlet Pipe

Venturi

Injector

Restrictor

(not on 40 models)

Fan, Collector and Cover

Assembly

Filter

Electrode

Leads

7.5

0.5

Spark Ignition Electrode

Sensing Electrode

Electrode Position

Viewing Window

Burner

13.2 Annual Servicing - Inspection (Cont)

6. Undo the nut on the gas inlet pipe to the venturi (Fig. 65) and pull the sensing pipe off the fan.

7. Disconnect the electrode leads, noting their position, and the fan electrical plugs (Fig. 66).

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

9. Carefully draw the fan, collector and cover assembly forward, being careful to retain the injector in the venturi (Figs. 65 & 66).

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

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

12. Reassemble in reverse order.

NOTE: The sensing pipe must be reconnected to the fan, not the venturi.

DHW Filter (Fig. 68)

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

14. Initially check the cold water inlet tap filter.

15. Turn the tap off and draw off from a hot tap. Undo the blanking cap and remove the threaded bush (Fig. 67).

16. Extract the filter and rinse thoroughly in clean water. Reassemble and check the flow. If required clean the restrictor filter as described below.

17. Pull off the hall effect sensor. Undo the restrictor from the inlet/return manifold.

18. Rinse the filter thoroughly in clean water and reassemble in reverse order.

19. Turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler.

20. 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.

Page 41

14.0 Changing Components

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 turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler before recommissioning.

See Section 13.2 “Annual Servicing” for removal of case panel, door etc.

14.1 Igniter (Fig. 69)

1. Disconnect the igniter feed plug and the electrode leads, noting their positions.

2. Undo the screw securing the bracket to the boiler.

3. Remove the igniter and transfer the bracket to the new component.

4. Reassemble in reverse order.

14.2 Spark and Sensing Electrodes (Fig. 70)

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.

Fig. 69

Igniter

Igniter Feed

Plug

Electrode

Leads

Bracket

Fig. 70

Spark

Electrode

Sensing

Electrode

Leads

Page 42

14.0 Changing Components

14.3 Fan (Fig. 71)

1. Undo the nut on the gas inlet pipe to the venturi (Fig. 49) and pull the sensing pipe off the fan.

2. Disconnect the electrode leads, noting their position and disconnect the fan electrical plugs.

3. Undo the screws securing the collector to the extension piece.

4. Remove the collector and fan assembly, being careful to retain the injector in the venturi.

5. Undo the screws securing the fan to the venturi and fit the new fan, replacing the seal if necessary.

6. Examine the burner gasket and replace if necessary.

7. Reassemble in reverse order, ensuring that the injector is in place and the sensing pipe is connected to the fan.

14.4 Venturi (Fig. 71)

1. Remove the collector and fan assembly as described in section 14.3.

2. Extract the injector from the venturi.

3. Undo the screws securing the fan to the venturi and the venturi to the collector.

IMPORTANT: When fitting the new venturi, ensure the arrows on it’s base point into the collector (Fig. 73).

4. Examine the seals and burner gasket, replace if necessary.

5. Reassemble in reverse order, ensuring that the injector is in place.

14.5 Injector (Fig. 71)

1. Remove the collector and fan assembly as described in section 14.3.

2. Extract and replace the injector and reassemble in reverse order.

Cover

Gas Inlet

Fan

Venturi

Injector

Collector

When fitting the venturi ensure that the arrow is

pointing forward

Fig. 71

Fig. 72

Gas Inlet Pipe

Venturi

Injector

Fig. 73

Page 43

14.0 Changing Components

Fig. 74

Cover

Burner

Gasket

Extension Piece

(Not on 33 & 40 models)

Collector

Venturi

Heat

Exchanger

Rear

Insulation

Cover

Insulation

Seal

Collector

Spark

Electrode

Sensing

Electrode

Leads

Venturi

Fig. 75

14.6 Burner (Fig. 74)

1. Undo the screws securing the collector to the venturi and extension piece. Remove this extension piece from the cover (on 24 and 28 models).

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

3. Examine the gasket, replacing if necessary.

4. Reassemble in reverse order.

14.7 Insulation (Fig. 75)

1. Remove the electrode leads, noting their positions. Also remove the electrodes as described in section 14.2.

2. Undo the screws securing the collector to the venturi and the nuts holding the cover to the heat exchanger. Draw the collector and cover assembly away.

3. Remove the cover insulation piece.

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

5. 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.

6. DO NOT remove the shrink-wrapped coating from the replacement rear insulation. Keep the insulation vertical and press firmly into position.

7. Examine the cover seal and replace if necessary.

Gasket

Page 44

14.0 Changing Components

14.8 Flue/Heat Exchanger Thermostat Sensor

(Fig. 76)

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.

14.9 Water Pressure Sensor (Fig. 78)

1. Drain the primary circuit.

2. Disconnect the two wires from the sensor.

3. Undo the nut on the flow pipe securing and sealing the sensor.

4. Remove the sensor, examine the sealing washer, replacing if necessary.

5. Reassemble in reverse order. The component is not polarised - either wire will fit each terminal.

14.10 Central Heating Temperature Sensor (NTC)

(Fig. 77)

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

2. Unscrew the sensor from it’s pocket and reassemble in reverse order. The plug will only fit one way.

14.11 Safety Thermostat (Fig. 77)

1. Pull the plug off the thermostat.

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

3. Reassemble in reverse order, ensuring that the plug is pushed fully on.

14.12 DHW Temperature Sensor (NTC) (Fig. 78)

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 plate heat exchanger manifold. Examine the sealing washer,replacing if necessary.

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

Central Heating

Temperature Sensor

Safety Thermostat

Flow Pipe

Fig. 77

DHW Temperature

Sensor

Fig. 78

Plate Heat Exchanger

Pressure Sensor

Flue/Heat Exchanger

Thermostat Sensor

Electrical

Plug

Fig. 76

Page 45

14.0 Changing Components

14.13 Pump - Head Only (Fig. 79)

1. Drain the primary circuit and remove the socket head screws securing the pump head to the body and draw the head away.

2. Undo the screw on the pump wiring cover and remove the cover. Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position.

3. A standard replacement Grundfos 15-60 head can now be fitted. Connect the pump wiring to the new head. The pump speed must be set to 3 (Fig. 80).

4. Reassemble in reverse order.

14.14 Pump - Complete (Fig. 81)

1. Drain the primary circuit.

2. Undo the two screws securing the body to the pipe and manifold and draw the pump forwards.

3. Undo the screw on the pump wiring cover and remove the cover. Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position.

4. Unscrew the automatic air vent from the pump body.

5. Connect the wiring to the new pump. Examine the ‘O’ ring seals on the return pipe and manifold, replacing if necessary.

6. Fit the air vent to the pump body and reassemble in reverse order.

14.15 Automatic Air Vent (Fig. 81)

1. Drain the primary circuit and unscrew the automatic air vent from the pump body.

2. Examine the ‘O’ ring seal, replacing if necessary, and fit it to the new automatic air vent.

3. Reassemble in reverse order.

Pump Setting

Socket Headed

Screw

Pump Head

Pump Body

Automatic Air

Vent

Fig. 79

Fig. 81

Fig. 80

Pump Wiring

Cover

Pump Wiring

Cover

Page 46

14.0 Changing Components

14.16 Pressure Gauge (Figs. 82 & 83)

1. Drain the primary circuit and undo the nut on the pressure gauge capillary.

2. Undo the screws securing the gauge retaining bracket.

3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining bracket.

4. Examine the sealing washer, replace if necessary.

5. Reassemble in reverse order.

14.17 Hall Effect Sensor (Fig. 84)

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.

14.18 Pressure Relief Valve (Fig. 85)

1. Drain the primary circuit.

2. Disconnect the discharge pipe from the valve. Using a suitable hexagon key undo the grub screw sufficiently to release the valve.

3. Note the orientation of the valve, rotate it and withdraw it from the manifold.

4. Fit the new valve and ‘O’ ring seal and set to the previously noted orientation. Reassemble in reverse order.

Pressure Gauge

Capillary

Gauge Retaining

Bracket

Fig. 82

Fig. 83

Pressure Relief Valve

Grub Screw

‘O’ ring seal

Discharge Pipe

Fig. 85

Hall Effect

Sensor

Hydraulic Inlet

Assembly

Fig. 84

Page 47

14.0 Changing Components

14.19 Plate Heat Exchanger (Fig. 86)

1. Drain the primary circuit and remove the gas valve as described in section 14.23.

2. While supporting the heat exchanger undo the screws securing it to the brass manifolds.

3. Withdraw the heat exchanger upwards, taking care not to damage any wires or controls.

Seals

4. There are four rubber seals between the manifolds and heat exchanger which may need replacement.

5. Ease the seals out of the manifold. Replace carefully, ensuring that when the seal is inserted into the manifold it is parallel and pushed fully in.

6. When fitting the new heat exchanger note that the left hand location stud is offset towards the centre more than the right hand one.

7. Reassemble in reverse order.

14.20 Diverter Valve - Motor Unit & Assembly (Fig. 87)

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

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

3. The motor unit 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.

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 any seals or washers, replacing if necessary. Transfer the DHW NTC to the new valve and reassemble in reverse order.

14.21 P.C.B. (Fig. 90)

1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins.

2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots. Disengage the rear of the cover from the control box hinge pin (Fig. 89).

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

4. Undo the securing screws and remove the P.C.B. Transfer the control knob drive pins to the new P.C.B. and turn them fully anticlockwise.

5. Reassemble in reverse order, ensuring that the temperature controllers are reset to their previous positions.

14.22 Selector Switch (Fig. 90)

1. Note the setting of the selector switch knob and carefully pull it off the facia.

2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots. Disengage the rear of the cover from the control box hinge pin (Fig. 89).

3. Note the position of the electrical connections and the orientation of the switch. Remove the electrical connections.

4. Remove the screws securing the switch to the facia panel.

5. Fit the new switch, ensuring that it is correctly positioned and reassemble in reverse order.

Plate Heat Exchanger

Rubber Seal

Fig. 86

Motor Unit

Multi-pin Plug

Retaining Clip

Valve

Assembly

Fig. 87

LH Location Stud

Pressure Sensor

Control Box Cover

P.C.B.

Selector

Switch

Facia

Selector Switch Knob

Temperature Control Knobs

Fig. 89

Fig. 90

Drive Pins

Page 48

14.0 Changing Components

14.23 Gas Valve (Fig. 91)

IMPORTANT: After replacing the valve the CO2must be checked and adjusted as detailed in Section 15.0 Setting the Gas Valve. Only change the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see section 13.1.

1. Turn the gas cock off and undo the nut on the gas feed elbow under the boiler.

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

3. Pull off the power lead, earth lead and sensing pipe.

4. Undo the nut on the gas pipe at the gas/air inlet and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Remove the valve.

5. Reassemble in reverse order., ensuring that all seals are in place and the injector is fitted.

NOTE: To assist the boiler to light prior to final setting, use a suitable hexagon key to wind out the Throttle Adjustment Screw until it is flush with the valve body, then turn the screw 4 full turns clockwise (Fig. 91a). If the boiler will not light, or the correct CO

cannot be achieved

contact the ‘heateam’ technical helpline.

14.24 Expansion Vessel (Fig. 92)

1. Drain the primary circuit and undo the nut on the vessel connection pipe.

2. Undo and remove the locknut securing the vessel spigot to the boiler air box.

3. Remove the bracket and vessel from the boiler.

4. Locate the retaining bracket on the upper flange of the vessel and fit to the boiler.

5. Reassemble in reverse order.

Gas Valve

Earth Lead

Gas Feed

Elbow

Fig. 91

Power Lead

Expansion Vessel

Boiler Chassis

Lock Nut

Fig. 92

Retaining Bracket

Sensing Pipe

Venturi Inlet

Pipe

Fig. 91a

Throttle

Adjustment Screw

Page 49

15.0 Combustion Check

Selector Switch

Display

bar

GRASSLIN

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Fig. 94

Fig. 95

Fig. 96

Fig. 97 Fig. 98

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Fig. 93

x 2

Fig. 99

Flue Adaptor Test

Point

Plug

Analyser Probe

15.1 Setting the Gas Valve (CO

check)

IMPORTANT: The CO

must be only be checked and adjusted to set the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see Section 13.1

1. The combustion (CO

) may be checked after running the boiler for several minutes. To do this it is necessary to set the boiler to ‘Calibration Mode’.

2. Ensure that all external controls are calling for heat. The actual current boiler temperature is shown on the display.

3. Turn both control knobs fully anticlockwise, then quickly turn the right hand knob

/4clockwise twice and back fully

anticlockwise (Fig. 93).

4. The display will now alternate between ‘SF’ and the current boiler temperature and both green LEDs will flash (Figs. 94 & 95).

5. Turn the left hand knob fully clockwise. As the knob is turned the display will change, indicating the fan speed.

6. The display will show ‘00’, indicating maximum rate, then revert to ‘P ‘ alternating with the current boiler temperature (Figs. 96, 97 & 98).

7. Remove the plug from the flue sampling test point. Insert the analyser probe and allow sufficient time for the reading to settle (Fig. 99).

The CO

should be 8.7% ± 0.2

8. It is possible to alter the CO

by adjustment of the gas valve. Remove the plastic cover from the Throttle Adjustment Screw. At maximum rate the Throttle Adjustment Screw should be turned, using a suitable hexagon key, until the correct reading is obtained (Fig. 100). Turning clockwise will reduce the CO

. Anticlockwise will

increase th e CO

9. The CO

must then be checked at minimum rate. Turn the left hand knob fully anti-clockwise. As the knob is turned the display will change, indicating the fan speed. When the display reads ‘ 0’ the boiler runs at minimum rate.

The CO

should be 8.4% ± 0.2

10. With the boiler on minimum, the Offset Adjustment Screw must be altered, using a suitable hexagon key, after removing the cap (Fig. 100). Turning anti-clockwise will reduce the CO

. Clockwise will increase th e CO2.

11. The ‘Calibration Function’ is maintained for 20 minutes unless the maximum CH temperature is exceeded. The function can be disabled at any time by turning the right hand knob.

12. Check the Combustion Performance (CO/CO

ratio).

This must be less than 0.004.

Throttle

Adjustment Screw

(cover removed)

Offset

Adjustment Screw

(cap fitted)

Gas Valve

Fig. 100

If the CO2is reset at minimum rate it must be rechecked at maximum rate again and adjusted if required. If the CO2is reset at maximum rate it must be rechecked at minimum rate and adjusted if required.

Do not turn the adjustment screws more than 1/8 of a turn at a time. Allow the analyser reading to settle before any further adjustment

Reduce CO

at min. rate

Increase CO

at min. rate

Reduce CO

at max. rate

Increase CO

at max. rate

Page 50

16.0 Electrical

- brown

- black

- blue

- white

br bk b w

- green

- green / yellow

- red

g g/y r

Control PCB

X2 X3

X501

1212 3344

556789

DHW NTC Sensor

Central Heating NTC Sensor

Fan

Gas Valve

Overheat Stat

Flame

Sensing

Electrode

Pump

Flue Sensor

X400

X401

g/y

Water Pressure Switch

Spark Generator

Ignition Electrode

9876

54321

910 8 7 6

54321

Hall Effect

Sensor

Diverter Valve

Timer

1234

g or w

Link

g/y

Mains Input Cable

16.1 Illustrated Wiring Diagram

Page 51

17.0 Short Parts List

Short Parts List

Key G.C. Description Manufacturers No. No. Part No.

311 Fan 5121447

426 Motor 3 way Valve 5132452

315 Igniter Electrode 720222801

316 Sensing Electrode 720222901

422 Gas Valve 720301001

Gas Valve (40 only) 5122286

624 Hall Effect Sensor 5114767

306 Burner (24/28) 5122149

Burner (33) 5114697

Burner (40) 5114698

419 Water Pressure Switch 5114748

400 Plate Heat Exchanger 5114708

415 Pump 248042

302 Flue Thermostat 5114747

421 NTC Sensor 5114725

420 Overheat Thermostat 5114729

504 Pressure Gauge 248090

503 PCB 24 5121862

PCB 28 720043401

PCB 33 720795201

PCB 40 5122287

306

426

315

316

311

422

624

419

400

415

302

421

420

503

504

Page 52

18.0 Fault Finding

NOTE: When instructed to turn the

selector to the reset position turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler.

18.1 Initial Fault Finding Checks

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

2. Electrical supply = 230V ~ 50 Hz.

3. CH water system pressurised to 0.5 bar minimum when the boiler is cold.

4. The preferred minimum gas pressure is 20 mbar.

5. 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.

6. 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.

18.2 Error Codes

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

2. The codes are either two or three digit, preceded by the letter 'E'. For example, code E133 will be displayed by 'E1' alternating with '33'. E50 is shown as 'E' then '50'

E20, E28 & E50 indicate faulty components.

E110 shows overheat of the primary water and E130 overheat of the flue system.

E119 is displayed when the primary water pressure is less than 0.5 bar.

E133 indicates that the gas supply has been interrupted, ignition has failed or the flame has not been detected.

E125 is displayed in either of two situations:i) If within 15 seconds of the burner lighting the boiler temperature has not changed by 1°. ii) If within 10 minutes of the burner lighting the boiler temperature twice exceeds the selected temperature by 30°. In these instances poor primary circulation is indicated.

3. By turning the selector switch to the 'Reset' position for a minimum of 5 seconds when E110, E130 & E133 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.

Central Heating NTC Fault Flue NTC Fault Hot Water NTC Fault Safety Thermostat Operated Water Pressure Switch Not Operated Circulation Fault (Primary Circuit) Flue NTC Operated Interruption Of Gas Supply or Flame Failure Fan or Fan Wiring Fault Pre-Circulation Fault

E20 E28 E50 E110 E119 E125 E130 E133 E160 E193

Table Of Error Codes

Page 53

18.0 Fault Finding

Refer to Section 16.0 “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence

Turn selector switch to

The display illuminates

Error 20, 28 or 50 flashing

Error 119 flashing

Burner lights

Error 110 flashing Error 130 flashing Error 133 flashing

Turn Central Heating

thermostat to Maximum.

Pump runs

Fan runs

Spark at ignition electrodes for

up to 5 seconds and for 3

attempts

3-way valve is open to Central

Heating circuit

Go to section ‘A’

Go to section ‘E’

Ensure all controls and

integral clock are calling for

heat

Go to section ‘K’

Go to section ‘B’

Error 160 flashing

Go to section ‘D’

Error 133 flashing

Burner does not stay alights

after 5 seconds

Error 133 flashing

Go to section ‘I’

Operation sequence

successful

If the error 110 is still flashing.

Go to section ‘J’

Fan runs at correct speed

YES

YES YES

YES

YES YES

YES

Burner output modulates to

maintain the temperature set

Burner goes out

Go to section ‘C’

Ensure controls are set to

demand and verify the

contacts are closed

Error 160 flashing

Go to section ‘L’

YES

Go to section ‘H’

Turn the selector switch to

reset

Go to section ‘F’

Error 130 flashing Go to section ‘M’

YES

Check the Central Heating

NTC sensor

Go to section ‘E’

Fan stops after 10 seconds

Pump continues to run for 3

minutes

(room thermostat open)

YES

Turn the selector switch to

reset position for 5 seconds

Error E125 or E193 flashing

Ensure that primary

circulation is OK & that

there is no blockage

YES

Page 54

18.0 Fault Finding

Turn selector switch to

The display illuminates

Error 20, 28 or 50 flashing

Error 119 flashing

Burner lights

Error 110 flashing Error 133 flashing

Turn Domestic Hot Water

thermostat to Maximum.

Open DHW tap fully.

DHW Hall Effect sensor

operated (red neon on the

sensor illuminated

Fan runs

Spark at ignition electrodes for

up to 5 seconds and for 3

attempts

3-way valve is open to

Domestic Hot Water circuit

Go to section ‘A’

Go to section ‘E’

Is mains water filter and

assembly clean?

Is the magnetic detector free

to move in the Hall Effect

sensor

Go to section ‘K’

Go to section ‘B’

Error 160 flashing Go to section ‘D’

Error 133 flashing

Burner does not stay alights

after 5 seconds

Error 133 flashing

Go to section ‘I’

Operation sequence

successful

Turn the selector switch to

reset position for 5 seconds

If the error 110 is still flashing.

Go to section ‘J’

Fan runs at correct speed

YES

YES YES

YES

Burner output modulates to

maintain the temperature set

DHW flow sensor senses no

flow. Burner goes out

Go to section ‘C’

DHW flow rate more than 2

l/min

Error 160 flashing

Go to section ‘L’

YES

Go to section ‘H’

Turn the selector switch to the

reset position for 5 seconds

Go to section ‘F’

Error 130 flashing Go to section ‘M’

YES

Reduce DHW flow rate

Burner modulates

Fan stops after 10 seconds

Pump runs for 30 seconds

YES

Domestic Hot Water - Follow operational sequence

Pump runs

YES

Error 125 flashing

Go to section ‘B’

Close DHW tap

YES

Clean DHW NTC sensor

and DHW heat exchanger

Page 55

18.0 Fault Finding

Fault Finding Solutions Sections

Is there 230V at:

Main terminals L and N Check electrical supply

Main terminal fuse Replace fuse

Replace PCB

Display illuminated

PCB - X1 connector terminals 1,2

Check wiring

Pump Replace pump

YES

PCB - X3 connector terminals 3 & 4 Replace PCB

Change pump supply cable

YES

CH system pressure less than 0.5 bar Re-pressurise system

YES

Check the tap of the automatic air vent is opened

Open the automatic air vent

YES

Fan connections correct at fan. PCB X2 connector, is 230V AC across terminals 3 & 4

Fan jammed or faulty winding

Replace PCB

Replace fan

YES

If pump jammed, release

Replace water pressure switch

Check connection water pressure switch terminal COM - NO and PCB connector X400 terminals 3,4

YES

Page 56

18.0 Fault Finding

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

Replace sensor

Gas at burner

Ensure gas is on and purged

Replace PCB

Replace gas valve

PCB - X3 connector is 230V AC across

terminals 1 & 2

YES

Replace PCB

Check and correct if necessary

1. Ignition electrode and lead

2. Electrode connection

3. Spark gap and position

YES

Replace igniter

YES

1. Ensure that the Hall Effect Sensor is in position.

Check the connection between the PCB - X400 connector terminals 3,6,7 and the electronic sensor

Check the voltage between red wire and blue wire is more than 5V DC

Replace PCB

Check and correct the connection of the

tube between the venturi and gas valve

Replace Hall Effect Sensor

YES

Voltage at PCB - X2 connector is at least 100V DC across terminals 2 & 5 (Note: from multimeter connect ‘common’ to 2 & ‘volts’ to 5). Check wiring

7.5

0.5

Spark Ignition Electrode

Sensing Electrode

Electrode Position

Viewing Window

Burner

Page 57

18.0 Fault Finding

Check and correct if necessary

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

2. Flame sensing electrode and lead connections

3. Flame sensing electrode position

Flame current should be more than 0.5 μ A

Replace PCB

YES

Replace flame sensing electrode

Check supply pressure at the

gas valve:-

Minimum 17 mbar

Replace safety thermostat

YES

Overheat thermostat operated or

faulty, i.e. continuity across

thermostat terminals

Allow to cool. Continuity

across thermostat terminals

more than 1.5 ohm

Is there 230V at:

Motor 3-way valve Replace motor 3-way valve

YES

PCB - X3 connector terminals 5 & 6 central heating mode 5 & 7 domestic hot water mode

Replace PCB

Change pump supply cable

YES

Fan connections correct at fan. PCB - X401 connector terminals 5,6,7 & 8

1. YES

Replace fan

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

Replace sensor

YES If pump is running the heat exchanger could be obstructed

Replace heat exchanger

Page 58

*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.

www.centralheating.co.uk

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 No

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 No

Yes No

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 59

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 60

UK Comp No5121651 - Iss 15 - 2/14

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

Baxi Platinum Combi 24 HE A, Platinum Combi 28 HE A, Platinum Combi 33 HE A, Platinum Combi 40 HE A Installation & Servicing Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual