Baxi Potterton Gold FSB 30 HE User Manual

You can rely on

Installation & Service Instructions

Gold

FSB 30 HE

Floor Standing

Condensing Boiler

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

Natural Gas

Potterton Gold FSB 30 HE

G.C. No. 41 592 32

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.

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With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn.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.

© Baxi Heating UK Ltd 2011 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner, except for permitted fair dealing under Copyrights, Designs and Patents Act 1988.

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

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

Full acknowledgement of author and source must be given.

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

0086

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

ISO 9001

FM 00866

Choose Building

Regulations Notification

Route

Installer Notification Guidelines

Competent Person's

Self Certification Scheme

Install and Commission this appliance to manufacturer's

instructions

Complete the

Benchmark Checklist

If you notify via the ‘Gas Safe

the Building Regulations

certificate on members’ behalf

Building Control

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact a government approved

inspector

Install and Commission this appliance to manufacturer's

instructions

Scheme Members only

Call ‘Gas Safe Register’ on:

0800 408 5577

or log onto:

www.gassaferegister.co.uk

within 10 days

You must ensure that the

certificate number issued by

the ‘Gas Safe Register’ is written

onto the Benchmark Checklist

‘Gas Safe Register’ will issue a

Building Regulations Compliance

Certificate to the property owner

and inform the relevant LABC

Complete the

Benchmark Checklist

LABC will record the data

and will issue a

certificate of compliance

Legislation

IMPORTANT - Installation, Commissioning, Service & Repair

This appliance must be installed in accordance with the manufacturer’s instructions and the regulations in force. Read the instructions fully before installing or using the appliance.

In GB, this must be carried out by a competent person as stated in the Gas Safety (Installation & Use) Regulations.

Definition of competence: A person who works for a Gas Safe registered company and holding current certificates in the relevant ACS modules, is deemed competent.

In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic Gas Installations”.

The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty. In GB this could also infringe the Gas Safety (Installation and Use) Regulations.

Warning - Check the information on the data plate is compatible with local supply conditions.

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

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).

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 0087.

Product/Production certified by: Notified Body 0086.

For GB/IE only.

Codes of Practice, most recent version should be used

In GB the following Codes of Practice apply: Standard Scope

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

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

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

BS 7593 Treatment of water in domestic hot water

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

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

BS 7074 Expansion vessels and ancillary equipment for BS 7593 Treatment of water in domestic hot water

purposes.

heating systems.

sealed water systems. central heating systems.

purposes.

heating systems. sealed water systems. central heating systems.

Contents

Section Page

1.0 Introduction 6

2.0 General Layout 7

3.0 Boiler Operation 8

4.0 Technical Data 9

5.0 Dimensions and Fixings 10

6.0 System Details 11

7.0 Site Requirements 15

8.0 Flue Options 20

9.0 Plume Displacement 25

10.0 Installation 29

11.0 Electrical 34

12.0 Commissioning the Boiler 36

13.0 Completion 38

14.0 Servicing the Boiler 39

15.0 Changing Components 42

16.0 Short Parts List 49

17.0 Fault Finding 50

Benchmark Checklist 58

Optional Integral Timer

Position of Label

Fig. 1

Facia Securing Screws

1.0 Introduction

1.1 Description

1. The Potterton Gold FSB 30 HE is a gas fired room sealed fan assisted condensing central heating boiler.

2. The maximum output of the boiler is 30.18 kW (Non Condensing) 32.61 kW (Condensing).

3. The boiler is designed for use on Natural Gas (G20) only.

4. The boiler is suitable for fully pumped open vented and sealed systems, providing heating and hot water.

5. A label giving details of the model, serial number and Gas Council number is situated on the rear of the drop down facia panel (Fig. 1).

6. The boiler data badge is positioned on the air box door (Fig. 2).

7. The boiler is intended to be installed in residential / commercial / light industrial E.M.C. environments on a governed meter supply only.

Air Box Door

Case Securing Screws

8. The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit, part no 236921.

1.2 Important Information

Man-made mineral fibre

• Some component parts of this boiler (insulation pads, gaskets and rope seals) are manufactured from man-made mineral fibre.

• Prolonged or excessive exposure to this material may result in some irritation to the eyes, skin or respiratory tract.

• It is advisable to wear gloves when handling these items.

• Irritant dust will only be released from the items if they are broken up or subjected to severe abrasion. In these instances a suitable dust mask and goggles should be worn.

• Always thoroughly wash hands after installation, servicing or changing components.

• When disposing of any items manufactured from manmade mineral fibre care must be exercised.

• If any irritation of the eyes or severe irritation of the skin is experienced seek medical attention.

Fig. 2

Data Badge

2.0 General Layout

2.1 Layout (Figs. 3, 4, 5 & 6)

1. Condensate Pump

2. Flue Elbow (supplied in std. flue kit)

3. Heat Exchanger

4. Burner

5. Air Box

6. Fan Protection Thermostat - Black

Fig. 5

15 14

7. Fan Assembly

8. Condensate Trap

9. PCB Housing Assembly

10. Gas Tap

11. Gas / Air Ratio Valve

12. Flow Pipe Connection

13. Return Pipe Connection

14. Flow Temperature Safety Thermostat - Black

15. Flow Temperature Thermistor - Red

16. Flow Switch (dry fire protection)

17. Position of Optional Integral Timer Wiring

18. Pipe Access Panel

19. Manual Air Vent

Fig. 3

2.2 110Ø Concentric Flues & Optional Extras

KIT PART N

Standard Flue Kit 850mm (inc. elbow) 236921 Extended Flue Kit - 1.75M ( inc. elbow) 5111457 Flue Plume Deflector Kit 248167 Terminal Guard (suitable for use with above) 248484

FLUE EXTENSION KITS (110/70) Flue Extension 250mm 241692 Flue Extension 500mm 241694 Flue Extension 1000mm Flue Bend x 2 - 45°

Flue Bend - 93° (

VERTICAL FLUE Vertical Flue Terminal 242802 Vertical Flue Adaptor 5106888

See Section 7.12 for more flue option details

Integral Twin Channel Timer 5117696

(Use two kits for 2M etc.) 241695

(Reduce overall length of flue

by 0.5m when fitting this bend)

Reduce overall length of flue by 1m when fitting each bend)

241689

241687

Fig. 4

Fig. 6

3.0 Boiler Operation

Mains On.

Flow

temperature less

than set point ?

YES

System Pump

Running and Flow

switch made ?

YES

5 second

Fan Pre-Purge.

5 second

Ignition Period.

YES

Condensate Pump will

operate as necessary (3.1.9)

Ignition done

and less than 5

attempts made ?

3.1 Boiler Operation

1. Switched Live On: When switched live is supplied to the boiler and the flow temperature is less than the set point the sequence below commences.

2. Flow Switch: After 10 seconds if the flow switch has made then fan pre-purge occurs. After 10 seconds if the flow switch has not made then anti-cycle occurs.

3. Fan Pre-Purge: The flow switch is made and the fan is on while the spark generator and gas valve are off. After 5 seconds ignition occurs.

4. Ignition: The flow switch is made, fan, spark generator and gas valve are on. If a flame is detected then burner on occurs. If a flame is not detected within 5 seconds and less than 5 ignition attempts have been made then fan purge occurs. If a flame is not detected within 5 seconds and 5 ignition attempts have been made then ignition lockout occurs.

5. Burner On: The flow switch is made, fan and gas valve are on while the spark generator is off. Flow temperature is controlled by varying the fan speed (and thereby the gas rate) to achieve optimum operation. If the flow temperature is greater than the set point or the TRVs all shut down then fan post purge occurs.

Flame Detected ?

shut or Flow temperature

greater than set point ?

Fan Post Purge.

YES

Burner On.

All TRVs

YES

5 second

All TRVs

shut down ?

Ignition done and 5 attempts made ?

YES

Ignition

Lockout.

6. Fan Post Purge: The fan is on while the spark generator and gas valve are off. After 5 seconds if the TRVs are shut down then anti-cycle occurs.

7. Anti-cycle: The fan, spark generator and gas valve are off.

8. Ignition Lockout: The fan, spark generator and gas valve are off. The boiler can only be reset by manually using the reset button.

9. Condensate Pump: Condensate accumulates in a reservoir within the pump assembly. The pump may run at any time, independent of boiler operation, to discharge the condensate to drain.

3 minute

Anti-cycle.

4.0 Technical Data

Appliance Type C Appliance Category CAT I

Heat Input (Q)(Gross) Max Min

kW 33.76 10.3

Heat Output (P)

(Non Condensing 70° C Mean Water Temp)

Max Min

kW 30.18 9.2

Heat Output (P)

(Condensing 40° C Mean Water Temp)

Max Min

kW 32.61 10.0

Max Gas Rate (2H - G20 - 20mbar) (After 10 Mins)

kW Input 33.76

/hr 3.4

Inlet Pressure at Gas Valve (Natural Gas)

Min 18.1 mbar Max 22.5 mbar

(see Section 10.1)

Injector (Natural Gas)

Diameter 6.5mm

CO/CO2 Ratio 0.004

NOxClass 5

Horizontal Flue Terminal Diameter - 110mm Dimensions Projection - 150mm

Connections

Gas Supply - 15mm Central Heating Flow - 28mm Central Heating Return - 28mm Condensate Drain (Pump) - 10mm o.d.

Outercase Dimensions

Casing Height - 850mm Casing Width - 390mm Casing Depth - 520mm

Minimum Clearances

(For unventilated compartments see Section 7.2)

Both Sides - 5mm Above Casing - 15mm Above Casing Under fixed worktop (It is recommended that any worktop is removable) - 25mm Front (For Servicing) - 500mm Front (In Operation) - 5mm

Weights kg Packaged Boiler Carton - 49.5 Packaged Flue Kit - 3.6 Installation Lift Weight - 37.5 Installed Weight (dry) - 44.5

Recommended System Temperature Drop

Condensing 20°C

Electrical Supply 230V~ 50Hz The boiler must be connected to an earthed supply. A permanent and switched live are required. The boiler has a 4 wire connection.

Power Consumption 80W

External Fuse Rating 3A

Internal Fuse Rating (BS 4265)

Fuse 3.15 AT (PCB)

Electrical Protection IPXX

Water Content

litres 2.6

Static Head

max 30 metres min 1 metre

Low Head 0.2m min System Detail

Fully pumped open vented & sealed systems. No bypass required.

Controls

boiler thermostat, safety thermostat, flow switch, electronic flame sensing, temperature protection thermostat & condensate blockage and level sensors

Boiler Flow Temperature (adjustable)

55° C to 78° C (± 5° C)

Condensate Pump

Head 3 metres Flow Rate 1.8 l/min Connection 10mm o.d. (pipe supplied)

SEDBUK Declaration

SAP 2005 Seasonal Efficiency

model is 90.9%

This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated has been certified by 0087.

Boiler Hydraulic Resistance Chart

220 200 180 160 140 120 100

80 60

Pressure Drop (mbar)

40 20

010203040

Water Flow Rate (litres/min)

91 83 75 66 58 50 42 33 25 17

Pressure Drop (in wg)

5.0 Dimensions and Fixings

DIMENSIONS

At least

1.5°

A 850mm B 520mm C 390mm

D 125mm Ø Min. E 175mm F 150mm

The 1.5° fall provided by the elbow is to allow condensate to run back to the boiler, for discharge through the

Flue Ø 110mm

condensate disposal system.

Fig. 7

Fig. 8

SIDE FLUE (left and right)

For every 1m of horizontal flue length, the clearance above the top

At least

1.5°

of the flue elbow should be 27.5mm to incorporate the 1.5° fall in the flue from the terminal to the elbow. It is

especially important to consider this when fitting the boiler under a work top !

Flue length (Y)

up to 1m

1m - 2m 2m - 3m 3m - 4m

Clearance (X)

27.5mm 55mm

82.5mm

110mm

6.0 System Details

6.1 Water Circulating Systems

1. The boiler is suitable for use with open vent fully pumped systems and sealed systems .

The following conditions should be observed on all systems:

•The static head must not exceed 30m of water.

•The boiler must not be used with a direct cylinder.

•Drain cocks should be fitted to all system low points.

•All gas and water pipes and electrical wiring must be installed in a way which would not restrict the servicing of the boiler.

•Position isolating valves as close to circulating pump as possible.

6.2 Treatment of Water Circulating

Systems

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

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

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

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

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

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

Boiler Air

Vent

Boiler Air

Vent

Fig. 9

Boiler

1000mm

Min

Copper

0.5m

Copper

500mm

150mm

Return

Max

45°

15mm Cold Feed

Copper

0.5m

22mm Open Vent

400mm

Min Head

Pump

Flow Return

Flow

6.0 System Details

6.3 Pipework

1. The sizes of flow and return pipes from the boiler should be determined by normal methods, according to the requirements of the system.

2. The connection tails for the boiler are 28mm diameter. The 28mm section of the tails can be cut back to 22mm if required.

3. The flow & return tails are push - fit ‘O’ ring and clip connections within the boiler case.

4. A 20 °C drop in temperature across the system is recommended for condensing boilers. Existing radiators may be oversized and so allow this, but where radiator sizing is marginal it may be advisable to retain a system temperature drop of 11°C.

5. In systems using non-metallic pipework it is necessary to use copper pipe for the boiler Flow and Return. The copper must extend at least 1 metre from the boiler and include any branches (Fig. 9).

Boiler Air

Vent

Fig. 10

Fig. 11

Boiler

Typical Low Head Installation

45°

15mm Cold Feed

22mm Open Vent

400mm

Min Head

150mm

Max

Return

500mm

1000mm

Min

If Conditions Require,

This System Possible

Pump

6. This boiler does not require a bypass.

6.4 Low Head Installation

1. Using a close couple arrangement the minimum head is as shown in the diagrams (Figs. 10 & 11) subject to the following conditions:

a) The pump being adjusted to give a 20°C drop across

the boiler. b) The pump must be fitted on the flow. c) The pump must be fitted in accordance with the

pump manufacturer's instructions. d) The open vent pipe must be taken up from a tee in a

horizontal section of the flow pipe.

Flow

2. For heads below 400mm then an alternative utilising a combined vent and feed pipe may be connected (Fig. 12). This must be a minimum of 22mm diameter. It is recommended that an air separator is fitted when using a combined feed and vent pipe.

6.5 Air Vents

Boiler Air

Vent

Fig. 12

200mm

Min

Boiler

22mm Feed & Vent Pipe

Air

Separator

Return

Alternative Low Head Installation

Pump

Flow

For correct operation of the flow switch the boiler and system MUST be completely vented.

1. A manual air vent is fitted on the flow pipe, to enable complete venting of the boiler. The pipe access panel must be removed to do this.

2. Additional vents should be fitted at suitable points on the system as required.

g/y

S Plan

Valve

Cylinder

Stat

Room

Stat

Boiler Connection

(4 Core Wire)

Pump

Timer

230V 50Hz

LNE

L N

CH on

HW on

LNE

S/L NE

Motor

S Plan

Valve

Motor

g/y

P/L

System Control

Wiring Centre

Key to colours

b-Blue br - Brown w-White o - Orange gr - Grey g/y - Green/Yellow

230V 50Hz

LNE

g/y

Room

Stat

6.0 System Details

6.6 System Controls & Wiring

This boiler requires a permanent live for operation of the condensate pump and frost protection.

Cylinder

Stat

Y Plan

Diverter

Valve

1. To comply with Part L1 of the Building Regulations the heating system into which the boiler is installed should include the following:

a) zone controls b) timing controls c) boiler control interlocks

System Control

S/L NE

P/L

Wiring Centre

Timer

L N

CH on HW on HW off

LNE

Pump

Y Plan, Room Thermostat System, CH Interlocked By Room Thermostat, DHW Interlocked By Cylinder Thermostat

At least the Radiator(s) near the Room Thermostat not TRV’d Pump run from Switched Live

Boiler Connection

(4 Core Wire)

2. Such a system needs to be fully pumped and must provide independent temperature and time control to both the heating and hot water circuits and have a boiler and system pump interlock.

3. The boiler should be controlled so that it operates on demand only. Where it is proposed to effect control by thermostatic radiator valves a room thermostat should also be provided to switch off the boiler when there is no demand for heating.

S Plan, Room Thermostat System, CH Interlocked By Room Thermostat, DHW Interlocked By Cylinder Thermostat

At least the Radiator(s) near the Room Thermostat not TRV’d Pump run from Switched Live

Table. 1

Safety

Valve

Fig. 13

Air

Vent

Pressure

Gauge

Boiler

System Drains at Low Point

Filling Point

Pump

Expansion Vessel

Max Boiler Flow

Temp = 82° C

Method of determining minimum expansion

vessel volume for sealed systems.

Vessel Charge Pressure (Bar)

Initial System

Pressure (Bar)

0.5

1.0

1.5

2.0

1.0

1.5

2.0

1.5

Example :-

System Volume = 75 litres

1.5

2.0

Vessel Charge Pressure = 1.0 bar Initial System Pressure = 1.5 bar

Then :-

75 x 0.152 = 11.4 litres Expansion Vessel Volume

NOTE

Where a vessel of the calculated size is not obtainable then

the next available larger size should be used.

3 Litre Top Up Bottle (if required)

Radiator Circuit

Multiply Total

Water Content Of

System By (Litres)

0.067

0.112

0.207

0.441

0.087

0.152

0.330

0.125

0.265

6.0 System Details

6.7 Sealed Systems (Fig. 13)

1. SAFETY VALVE - A safety valve complying with the requirements of BS 6750 Part 1 must be fitted close to the boiler on the flow pipe by means of a horizontal or vertically upward connection with no intervening valve or restrictions and should be positioned to facilitate testing. The valve should be pre-set and non-adjustable to operate at a pressure of 3 bar (45 Ibf/in arranged to discharge any water or steam through a pipe to a safe outlet position.

2. PRESSURE GAUGE - A pressure gauge of minimum range 0-4 bar (0-60 Ibf/in

) with a fill pressure indicator must be fitted to the system, preferably at the same point as the expansion vessel in an easily visible position.

3. EXPANSION VESSEL - An expansion vessel complying with the requirements of BS 4814 must be fitted to the system by means of a connection close to the inlet side of the circulating pump in accordance with the manufacturers instructions, the connecting pipe being unrestricted and not less than 15mm ( The volume of the vessel should be suitable for the system water content and the nitrogen or air charge pressure should not be less than the system static head (See Table. 1).

Further details of sealed system design can be obtained from BS 5449 and the British Gas publication entitled 'Specifications for Domestic Wet Central Heating Systems'.

4. FILLING POINT - 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. The sealed primary circuits may be filled or replenished by means of a temporary connection between the primary 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. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment. Your attention is drawn to, for GB: Guidance G24.2 and recommendation R24.2 of the Water Regulations Guide. for IE: the current edition of I.S. 813 “Domestic Gas Installations”.

5. MAKE UP SYSTEM - A method of replacing water lost from the system should be provided either by means of a make up vessel of not more than 3 litres (5 pints) capacity, mounted above the highest point of the system, or by re-pressurisation of the system.

). It must be

/2in) nominal size.

Fig. 14

Mains Inlet

Stop Valve

Double Check Valve

Temporary Hose

Stop Valve

6. VENTING - A method of venting the system during filling and commissioning must be provided by fitting automatic air vents or by venting manually.

7. HOT WATER STORAGE - The hot water storage vessel must be of the indirect coil type.

8. COMPONENTS - All components used in the system must be suitable for operation at 110°C (230°F) and at the pressure allowed by the safety valve.

CH Return

Zone 1

Zone 2

Window Recess

Zone 2

7.0 Site Requirements

7.1 Location

NOTE: Due to the high efficiency 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 boiler must be fitted on a suitable flat and level surface capable of supporting the weight. Any wall behind the boiler must be at 90° to the floor to allow case top cover to fit correctly.

2. The flue must pass through an outside wall or roof and discharge to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply.

Fig. A

Zone 1

Zone 0

Window Recess

Zone 2

0.6 m

In GB Only

Window Recess Zone 2

Zone 2

2.25 m

Ceiling

Outside Zones

3. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse.

4. The boiler incorporates a frost protection device. This will only protect the boiler. To ensure protection of the system pipework and components it is recommended to incorporate an appropriate device within the system controls.

5. If the boiler is fitted in a room containing a bath or shower, it can only be fitted in Zone 3, (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.

6. 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).

Fig. B

0.6 m

In GB Only

7.2 Compartment

1. Where the boiler is installed in a cupboard or compartment, no air vents are required for cooling purposes providing that the minimum dimensions below are maintained.

Width 400mm Height 875mm Depth 525mm

2. Any compartment should be large enough to house the boiler only.

5mm Min

390mm

5mm Min

15mm Min (25mm if under non removable worktop)

7.0 Site Requirements

7.3 Clearances (Figs. 15 &16)

1. 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. For side flue installations also See Section 8.1, Figs. 20 & 21.

2. It is recommended that any worktop is removable for servicing access.

Fig. 15

850mm

7.4 Gas Supply

1. Check that the information concerning the state of adjustment given on the data plate is compatible with local supply conditions.

2. 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”.

3. The connection to the boiler is a 15mm tail on the gas service cock. The tail protrudes through the boiler rear panel and is protected by a transit bracket which may be removed to aid connection.

4. Ensure that the pipework from the meter to the boiler is of adequate size. (If the boiler is further than 3 metres from the Gas Meter 22mm pipe should be used). Do not

use pipes of a smaller diameter than the boiler gas connection.

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.

500mm Min

For Servicing

Purposes

5mm Min

Fig. 16

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

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

Connection may be via a fused double-pole isolator with a contact separation of at least 3mm in all poles, which must be in an accessible position to the user and serve the boiler and system controls only.

There is no method of isolating the boiler at the user interface.

3. Four core cable is required to supply the boiler as a permanent live is necessary for the operation of the condensate pump and frost protection.

520mm

In Operation

7.0 Site Requirements

Head (metres)

1.5

Min. radius 100mm

Point ‘A’

Condensate Pump Flow Graph

2.5

Flow (l/min)

3.5

Gravity Drain min. fall 3°

7.6 Condensate Drain - General

Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler.

1. Ensure the discharge of condensate complies with any national or local regulations in force.

BS 6798 & Part H1 of the Building Regulations give further guidance.

2. If any further drain pipe is required (additional to that supplied with the boiler), it should be run in a proprietary material e.g. PVC, PVC-U, ABS, PVC-C or PP.

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

4. Any pipe fitted externally must be kept as short as possible to minimise the potential of freezing and must be insulated using waterproof material.

5. When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered.

7.7 Condensate Disposal

Fig. A

Boiler

Max. Head

3 metres

Note: The point of discharge from the pumped length of condensate pipe (point ‘A’) must not be below the level of the pump, whether discharging direct into a drain or into an additional gravity drain.

Alternative Horizontal

Discharge

10mm PVC Pipe

(8.5mm I.D.)

Securing Clip

8.5mm Ø O.D.

1. This boiler incorporates an automatic pumped condensate system. See the graph opposite for available pump flow rates.

2. 3.5 metres of flexible 10mm PVC pipe are supplied with the boiler. 0.5 metres of this length remains coiled within the boiler to allow removal of the pump assembly. This must not be uncoiled to provide extra length.

3. A fitting and securing clip (Fig. B) to accept the 10mm PVC pipe and connect to 21.5mm overflow pipe is also supplied.

4. The 10mm pipe can be routed to a maximum of 3 metres vertically and then discharge via gravity or be routed horizontally (Fig. A). A combination of vertical and horizontal runs is permissible.

5. The pipe must be supported, either using suitably spaced clips or run within larger diameter pipe. When using clips take care not to deform the pipe.

6. When routing the pipe through a wall it must be suitably sleeved. Also the pipe must not be exposed to sources of heat, and should be protected in locations where it may be damaged.

7. The pipe should be routed so that any sharp bends, dips and loops are avoided. A minimum radius of 100mm is recommended for any bends. No slope is necessary and air breaks are not required on the pumped part of the condensate run.

Condensate Pipe Direct Connect Fitting

Fig. B

21.5mm Ø O.D. to fit

Overflow Pipe

8. If the boiler is fitted in an unheated location the entire length of condensate pipe should be treated as external, and run within insulated larger diameter pipe.

7.0 Site Requirement

10°

Termination via internal discharge branch e.g sink waste - downstream

Direct Connect Fitting

Sink

From Boiler

Fig. C

Pipe must terminate above water level but below surrounding surface

From Boiler

Branch of Tee to be ± 10° from vertical

Termination to an internal soil and vent pipe

Direct Connect Fitting

Min. 450mm

Fig. D

7.7 Condensate Disposal (cont.)

9. Ensure that the condensate can discharge freely (without blockage or restriction of the pipe) into the drain.

10. Examples are shown of condensate pipe methods of termination:-

i) via an internal discharge branch

(e.g. sink waste) - Fig. C.

ii) to an internal or external soil and vent pipe -

Fig. D.

iii) to a drain or gully - Fig. E. Ensure that the

condensate can discharge freely (without blockage or restriction of the pipe) into the drain.

iv) to a soakaway - Fig. F.

Termination to a drain or gully

From Boiler

Fig. E

Pipe must terminate above water level but below surrounding surface

Termination to a purpose made soak-away

From Boiler

Fig. F

500mm Min

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

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Baxi Potterton Gold FSB 30 HE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual