Baxi Potterton Gold HE A Range User Manual

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Installation & Service Instructions

These instructions include the Benchmark Commissioning

Checklist and should be left with the user for safe keeping.

Gold HE A

Range

Condensing

Combination Boiler

You can rely on

Natural Gas

Potterton Gold Combi 24 HE A

G.C.No47 393 18

Potterton Gold Combi 28 HE

G.C.No47 393 19

Potterton Gold Combi 33 HE A

G.C.No47 393 20

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.

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With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn.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

Baxi Heating UK Ltd is a

BS-EN ISO 9001 Accredited Company

The code of practice for the installation,

commissioning & servicing of central

heating systems.

“Potterton” supports

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, The Wyvern Business Park, Stanier Way, Derby, DE21 6BF.

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.

This product has an energy rating (A) on a scale of A to G.

For more information see www.boilers.org.uk. This is a certification mark.

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Competent Person's

Self Certification Scheme

Install and Commission this appliance to manufacturer's

instructions

Complete the

Benchmark Checklist

If you notify via CORGI Scheme,

CORGI will then notify the

relevant Local Authority

Building Control Scheme

on member's 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 CORGI on: 0800 408 1007

www.corgi-notify.com

You must ensure that the

notification number issued by

CORGI is written onto the

Benchmark Checklist

CORGI will record the data and

will send a certificate of

compliance to the property

Complete the

Benchmark Checklist

or log onto:

within 10 days

LABC will record the data

and will issue a

certificate of compliance

Legislation

Codes of Practice - refer to the most recent version

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 CORGI 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 CORGI registered installers carry a CORGI identification card and have a registration number. You can check your installer is registered by telephoning 0800 915 0485 or writing to:-

1 Elmwood,

Chineham Park,

Crockford Lane,

Basingstoke. RG24 8WG

or check online at www.trustcorgi.com

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 CORGI 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 5449 Forced circulation hot water 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 5449 Forced circulation hot water 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 Body 0085 & 0086.

For GB/IE only.

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 !!

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 19

9.0 Plume Displacement 24

10.0 Installation 28

11.0 Commissioning 34

12.0 Completion 37

13.0 Servicing 38

14.0 Changing Components 40

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

1.0 Introduction

1.1 Description

1. The Potterton Gold 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)

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

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

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

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 rear or the lower door panel. This is for user reference.

8. The boiler is intended to be installed in residential / commercial / light industrial E.M.C. 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 flue kit, part no.

5118489.

9. All systems must be thoroughly flushed and treated with

inhibitor (see section 6.2).

1.2 Contents of Pack

1. Boiler Unit

2. Wall Plate (inc. taps)

3. Set of Pipe (inc. nuts)

4. Template

5. Quick Fit Guide

6. Literature Pack

7. Filling Loop

Fig. 1

Lower Door Panel

Case Front Panel

Data Badge

Information Label

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. Optional Integral Timer Position

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. Integral Timer

Reset

bar

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.

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 Electrodes 4 Flame Sensing Electrode 5 Gas Valve 6Pump 7 Automatic Air Vent 8 Plate Heat Exchanger 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 19 Automatic By-Pass 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 27 Heat Exchanger Air Vent

Key

Central Heating Circuit

Domestic Hot Water Circuit

Fig. 3

5 6

1213141516

Fig. 2

4.0 Technical Data

4.1 Gold Combi 24, 28 & 33 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

Central Heating Primary Circuit Pressures

bar Safety Discharge 3 Max Operating 2.5 Min Operating 0.5 Recommended Operating Range 1-2

DHW Circuit bar Pressures

Max Operating 8 Min Operating 0.15

Flow Rates (24) (28) (33)

l/min l/min l/min DHW Flow Rate @ 30o C Rise 11.43 13.3 15.7

DHW Flow Rate @ 35o C Rise 9.8 11.5 13.5

Min Working DHW Flow Rate 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) Max Capacity of litre litre 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 200 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)

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

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

Electrical Supply 230V~ 50H

(Appliance must be connected to an earthed supply)

Power Consumption

155W (24 & 28 model) 160W (33 model)

Electrical Protection

IPX0D

Internal Fuse Rating F2L

Appliance Category CAT I

Inlet Pressure (Natural Gas - G20)

mbar 20

Injector (Natural Gas - G20)

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

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

Heat Input DHW (Net) Max

24 model kW 24.7

28 model kW 28.9

33 model kW 34

Heat Output DHW Max

24 model kW 24

28 model kW 28

33 model kW 33

Max Gas Rate (Natural Gas - G20)

(After 10 mins)

24 model m3/h 2.61

28 model m

/h 3.1

33 model m

/h 3.6

Condensate Drain

To accept 21.5mm (3/4in) 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

Heat Input DHW (Gross) Max

24 model kW 27.4

28 model kW 32.1

33 model kW 37.7

External Fuse Rating 3A

The efficiency is 91.1% (all models)

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.

SEDBUK Declaration

Weights (kg)

(24) (28) (33)

Packaged Boiler Carton 48.6 49.2 51 Installation Lift Weight 43.6 44.2 46

Pump - Available Head

5.5

4.5

3.5

2.5

Metre (wg)

1.5

0.5

200 400 600 800 1000 1200

Flow Rate (l/h)

5.0 Dimensions and Fixings

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

Flue Ø 100mm

At least 1.5°

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

6.0 System Details

6.1 Information

1. The Potterton Gold 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

• All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems.

• When fitting new systems flux will be evident within the system, which can lead to damage of system components.

• All systems must be thoroughly drained and flushed out. Using, for example Betz-Dearborn Sentinel X300 or X400 or Fernox Superfloc Universal Cleanser. They should be used following the flushing agent manufacturer’s instructions.

• System additives - corrosion inhibitors and flushing agents/descalers should comply to BS7593 requirements, e.g. Betz-Dearborn Sentinel X100 and Fernox-Copal which should be used following the inhibitor manufacturer’s instructions.

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

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

• For information or advice regarding any of the above contact Technical Enquiries.

6.3 Bypass

1. The boiler is fitted with an automatic integral bypass.

6.4 System Control

1. A 24 hour electro - mechanical timer is supplied fitted to the boiler.

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

6.0 System Details

6.5 System Filling and Pressurising (Fig. 4)

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.

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 (24, 28 models) 155 litres (33 models). 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 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 Hose

Pressure Relief Valve

Discharge Pipe

Stop Valve

Filling Loop

Fig. 5

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. A single check valve must be fitted as shown in Fig. 7 to prevent backflow to the supply pipe and to ensure the efficient operation of the expansion vessel which is required to accommodate the thermal expansion of the water.

4. When the domestic water system includes any device which prevents water expanding back towards the supply (check valve, loose jumpered stopcock, water meter, water treatment device) then an expansion vessel must be fitted (eg. Zilmet 160ml, R

/215bar).

5. If the hot water expansion is not provided for, then high pressures can develop which may result in damage to fittings and devices on the system.

6. 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

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).

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.

200mm 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°

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. 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. As the boiler is fitted with an integral timer when installed in a room containing a bath or shower it cannot be fitted in zones 1 or 2. (Figs. 11 & 12 shows zone dimensions for a bathtub. For other examples refer to Section 601 of 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

Zone 3

Zone 2

Window Recess

0.6 m

2.4 m

Ceiling

Outside Zones

Zone 3

Zone 2

Zone 1

Zone 0

2.25 m

Zone 2

Window Recess

3.0 m

2.4 m

0.6 m

Fig. 11

Fig. 12

In GB Only

7.0 Site Requirements

7.7 Condensate Drain

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

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.

1. The condensate outlet will accept 21.5mm (3/4in) 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.

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

BS 6798:2000 & Part H1 of the Building Regulations give further 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 to prevent sagging.

6. It is advisable to keep the condensate pipe internal.

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

should use 32mm waste pipe.

8. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run.

9. 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.

10. 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.

Examples are shown of the following methods of termination:i) to an internal soil & vent pipe - Fig. 13 ii) via an internal discharge branch (e.g. sink waste) - Fig. 14 iii) to a drain or gully - Fig. 15 iv) to a purpose made soakaway - Fig. 16

Boiler

2.5° Minimum fall

Termination to an internal soil and

vent pipe

450mm min

Boiler

2.5° Minimum fall

External termination via internal discharge

branch

e.g sink waste - downstream

Sink

Pipe must terminate above water level but below surrounding surface

Boiler

Pipe must terminate above water level but below surrounding surface

2.5° Minimum fall

Termination to a drain or gully

Boiler

500mm min

2.5° Minimum fall

Termination to a purpose made soak-

away

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

50mm per metre of pipe run

Fig. 13

Fig. 14

Fig. 15

Fig. 16

7.0 Site Requirements

7.8 Flue

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

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

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

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

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:

• Only ONE 25mm clearance is allowed per installation.

• 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.

Fig. 18

Fig. 17

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

Terminal Position with Minimum Distance (Fig. 18) (mm)

AaDirectly below an opening, air brick, opening

windows, etc. 300 BaAbove an opening, air brick, opening window etc. 300 CaHorizontally to an opening, air brick, opening window etc. 300 D Below gutters, soil pipes or drain pipes. 25 E Below eaves. 25 F Below balconies or car port roof. 25 G From a vertical drain pipe or soil pipe. 25 H From an internal or external corner. 25 I Above ground, roof or balcony level. 300 J From a surface or boundary line facing a terminal. 600 K From a terminal facing a terminal (Horizontal flue). 1200

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

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

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. See BS 5440 Pt. 1.

Opening Window or Door

100mm MIN.

IMPORTANT: If fitting a Plume Displacement Flue Kit, the air inlet must be a minimum of 100mm from any opening windows or doors (see Section 9.0).

Plume Displacement Kit

Air Inlet

Fig. 18a

J,K

Likely flue positions requiring a flue terminal guard

8.0 Flue Options

Horizontal Flues

Plume Displacement Kit 60 /100 Ø

1M Extensions, 45° & 93° bends are

also available - see Section 9.0

This bend is equivalent to 1 metre

Total equivalent length =

A+B+C+2x90°Bends

This bend is equivalent to 1 metre

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

Twin Flue Pipe

135° bend 0.25 metres

91.5° bend 0.50 metres

4. The elbow connected to the boiler adaptor is not included

in any equivalent length calculations.

5. The illustrations opposite show examples of permissible

flue systems.

NOTE: Flue length is measured from point X to Y as shown.

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.

8.0 Flue Options

Vertical Flues (Twin Pipe)

Vertical Flues

The total equivalent length for this example is

= 6.5 metres.

1m extension

135°bend

91.5°bend

0.25m

0.5m

5.0m

0.5m

1.0m

AIR DUCT

Noof

fittings/pipes

Sub total

Equivalent

Length Value

Equivalent Length Air Duct = 6.5m

1m extension

135°bend

91.5°bend

0.25m

0.5m

5.0m

0.5m

1.0m

FLUE DUCT

Noof

fittings/pipes

Sub total

Equivalent

Length Value

Equivalent Length Flue Duct = 6.5m

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 (point X) to the joint with the flue terminal (point Y). 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

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 X to Y as shown.

8.0 Flue Options

K,K1

U,W

Key Accessory Size Code No

FLUE GROUP A Concentric Flue System 100mm diameter

A3 Telescopic Internal Flue Kit 315-500mm 5119654 A2 Telescopic Flue (inc. elbow) 315-500mm 5118069 A Horizontal Flue Terminal (inc. elbow) 5118489 B Flue Extension 1000mm 5111074 C Flue Bend 93° 5111075 D Flue Bend 135° 5111076 D Flue Bend (pair) 135° 5111085 U Pipe Support (painted) 100Ømm 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 5111079 H Vertical Flue Adaptor 5111084 W Pipe Support (pair) 80mm 5111081 Y Flue Termination Kit

(horizontal termination) 80mm 5120172

FLUE GROUP G Concentric 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 U Pipe support 125mm 5118610

FLUE GROUP A, N, G Vertical Flue Kits

K Vertical Flue Terminal

(use with 5111070) 5111078

K1 Vertical Flue Terminal 5118576 L Pitched Roof Flashing 25°/50° 5122151 M Roof cover plate 246143 N Flat roof flashing 246144

8.3 Flue Accessories

8.0 Flue Options

For Twin Flue Systems fit the adaptors as follows:-

8.4 Flue Duct Adaptor

1. Engage the flue duct adaptor on the boiler adaptor,

making sure that it is pushed down as far as possible.

8.5 Air duct adaptor

1. Undo the screws securing the blanking plate to the boiler

top panel. Discard the plate.

2. There are three restrictor plates supplied in the kit. One

marked ‘23’ and one marked ‘27’, these can be discarded

The third restrictor MUST be positioned as shown in the diagrams below.

3. Take one of the gaskets supplied in the kit and place on

the boiler top panel.

4. Align the appropriate restrictor as shown. Position the

second gasket over the restrictor.

5. Using the screws previously removed secure the inlet

adaptor to the top panel.

6. Continue to fit the twin flue system.

Flue Duct Adaptor

Boiler Adaptor

Air Duct Adaptor

Gasket

Restrictor

Gasket

Position of Restrictor

Blanking Plate

24 kW models

28/33 kW models

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 100mm and 685mm from elbow to terminal (Fig. 19).

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. 21)

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 (Fig. 20)

1. If required, push the flue deflector over the terminal end and

rotate to the optimum angle for deflecting plume. Secure the deflector to the terminal with screws provided.

8.0 Flue Options

Fig. 19

Fig. 21

100mm 685mm

Push Fit Adaptor

Air Duct

Flue Duct

Cut the same amount off the Air Duct & Flue Duct

Approx

1425mm

Flue Deflector

Fig. 20

9.0 Plume Displacement

9.1 Plume Displacement Kit (Fig. 23)

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 Boiler 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. 24 &

25), and be at least 2 metres above ground level. It must be secured as shown in Fig. 19. The plume outlet must also be at least 500mm from the air inlet in any direction (Fig. 25).

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° bend) or 0.5 metres (45° bend).

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. 24

Fig. 25

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. 23

Fig. 22

9.0 Plume Displacement

Concentric 60/100 Flue

60Ø Exhaust

Fig. 26

Fig. 27

Flue Length - Worked Example Potterton Gold Combi 33HE

In Fig. 27 opposite an additional 93° bend 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

A - 93° Elbow 5121369 B - 45° Elbow (Pair) 5121370 C - 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 in Fig. 4 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 bend equivalencies must be accounted for i.e. 93° bends are equal to 1 metre, each 45° bend to 0.5 metres.

Example 1

Flue Lengths - Not Permissible

Example 2

Flue Lengths - OK

Example 3

Flue Lengths - OK

60 Ø Exhaust (metres) X

28/33

34 65798

Concentric 60/100 Flue (metres) Y

60 Ø Exhaust (metres) X

Concentric 60/100 Flue (metres) Y

60 Ø Exhaust (metres) X

28/33

34 65798

28/33

34 65798

Concentric 60/100 Flue (metres) Y

Min. 2 metres

Fig. 28

Fig. 33

30mm

Fig. 30

Fig. 32

Fig. 31

Adaptor

9.0 Plume Displacement

Flue Trim

Position of ‘Jubilee’ Clip screw

Fig. 29

Spigot

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 least 1.5°.

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

30mm

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. 34.

17. To do this, first slacken the two screws retaining the

plume outlet to the elbow, and remove the outlet (Fig. 35). The elbow can now be used to connect the vertical to horizontal 60Ø exhaust (Fig. 34). 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. 36).

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. 37) 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. 38), 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.

30mm

Fig. 35

Fig. 36

Fig. 34

Fig. 37

Plume Outlet

Elbow

Fig. 38

Outlet Spigot

Concentric Flue Length (shown end-on)

500mm Min.

200mm Min.

70°

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. 39 & 40).

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. 41).

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.

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. 42 & 43).

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

Fig. 43

145mm

For Side Flue Exit

Central Heating Return

Flushing Tube

Wall Plate

Fig. 41

Fig. 39

Fig. 40

Fig. 42

10.0 Installation

10.3 Fitting the Filling Loop

1. The filling loop supplied with the boiler can be

connected to the taps on the wall plate at this point.

2. The filling loop is to be connected between the mains

cold water inlet and central heating return isolation taps.

3. The loop and valves must be connected as shown in

the diagram (Fig. 44a).

4. Note the orientation of the flow direction arrows on

the stop valve and double check/stop valves.

5. Remove the end caps from the isolation taps and put

to one side. Connect the valves to the taps. Ensure that the fibre washers supplied are used on these joints.

6. Connect the temporary loop, ensuring that the seals

are fitted.

To fill, test and flush if required (Fig. 44c)

7. Take the blanking plugs from the kit, and using washers

supplied with the boiler, connect them to the central heating flow and return taps, and the cold inlet tap. The system can now be filled by opening the cold inlet supply and stop valves.

8. If desired a suitable gauge can be connected to one of

the taps so that the system may be accurately pressurised.

9. All joints, fittings and system components can now be

examined for soundness at operating pressure.

10. The system can be flushed by turning off the central

heating tap and connecting a suitable fitting to the loose nut. From the fitting a hose pipe can be run to the nearest convenient drain. When the tap is reopened the system will flush.

11. Remove the blanking plug(s), pressure gauge and

flushing equipment from the appliance if used.

12. Continue with the installation and commissioning.

13. The filling loop must be disconnected and completely

removed after the system is pressurised.

14. Hand tighten the two previously removed end caps

to the stop valve and double check valve.

Fig. 44a

Fig. 44c

CH Return

Cold Inlet

Double Check Valve & Stop Valve

Stop Valve

Temporary Filling Loop

Fitting the Valves to the Taps

Temporary Loop and Flanged Washers

Blanking Plugs

Pressure Gauge

Hose and Fitting

Fig. 44b

10.0 Installation

10.4 Fitting The Boiler

1. Lift the boiler using the Lifting Points as shown by the

shaded areas (Fig. 45). The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig. 46) (see Safe Manual Handling page 5).

2. Ease the boiler forwards and remove the sealing caps from

the boiler connections.

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

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

the wall plate and the boiler connections. THE RUBBER WASHERS MUST BE USED ON THE GAS CONNECTION.

4. Tighten all the connections.

10.5 Fitting the Pressure Relief Discharge Pipe

(Fig. 47)

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.

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.

10.6 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. 47

Pressure Relief Valve

Discharge Pipe

Fig. 45

Wall Plate

Suggested Lifting Points

shown as shaded area

Fig. 46

10.0 Installation

10.7 Fitting The Flue

HORIZONTAL FLUE

1. The standard flue is suitable for lengths between 100mm minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (Fig. 48).

2. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (Fig. 50). The elbow is fully engaged when there is a distance of 20mm from the adaptor to the indicator line (Fig. 49).

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

3. Measure the distance from the outside wall face to the elbow. This dimension will be known as ‘X’ (Fig. 51).

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

IMPORTANT: Check all dimensions before cutting.

5. Mark dimension ‘Y’ on the flue as shown (Fig. 52). Carefully cut the waste material from the flue, ensuring that the ducts are square and free from burrs.

Fig. 52

Wall Thickness

(X)

Wall Thickness

(X)

Flue Elbow

Fig. 48

Fig. 50

Adaptor

Apply Lubricant for ease of assembly.

Ensure Elbow is fully engaged into Boiler Adaptor

Fig. 51

100mm 685mm

Flue

Waste

Fig. 49

20mm

Indicator line

10.0 Installation

10.7 Fitting the Flue (Cont)

6. The inner flue duct support bracket may be in the waste portion of the flue. In this case retrieve the bracket before discarding the waste.

7. Take the inner flue support bracket (if not already fitted) and engage it over the flue duct. This will centralise the flue and air ducts, and ease assembly (Fig. 53).

8. Insert the flue through the hole in the wall. Fit the elbow to the boiler adaptor, ensuring that it is pushed fully in.

9. 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. 54).

10. Ensure that the terminal is positioned with the slots to the bottom (Fig. 55).

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

11. Make good between the wall and air duct outside the building.

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

CONCENTRIC VERTICAL FLUE

13. 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.

14. Measure 25mm from the end of the flue extension and apply a length of tape around the outer duct (Fig. 56).

15. Engage the extension into the adaptor up to this position (Fig. 57). Once the installation of the flue is complete and all support brackets are securely in place remove the tape.

Slots at bottom

Inner Flue Support Bracket

Fig. 53

Fig. 54

Fig. 55

Apply Lubricant for ease of assembly.

Ensure Flue is fully engaged into Flue Elbow

Adaptor

Apply Lubricant for ease of assembly.

Ensure Extension is fully engaged into Boiler Adaptor

25mm

Extension

Cut End

Fig. 56

Tape

Fig. 57

10.0 Installation

Fig. 59

Fig. 58

Cable Clamp

Facia Panel

Terminal Block Cover

10.8 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. 58).

3. Undo the terminal block cover securing screw and remove the cover (Fig. 58).

4. Slacken the unused cable clamp on the LH side of the boiler chassis (Fig. 59). 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 (Figs. 60 & 61). If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Figs. 60 & 61.

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.

Fig. 60

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.

Fig. 61

Fused Spur

Room ‘Stat

g/y

230V

Frost Thermostat

Room ‘Stat

230V

External Clock

230V

g/y

11.0 Commissioning

11.1 Commissioning the Boiler

1. Reference should be made to BS 5449 Section 5 when commissioning the boiler.

2. Open the mains water supply to the boiler.

IMPORTANT: The heat exchanger air vent on top of the boiler (Fig. 62) MUST be opened before filling the primary system.

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

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

5. Open the screw on the automatic air vent on the pump body (Fig. 63).

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

7. Pressurise the system to 1.5 bar (Fig. 64) then close and disconnect the filling loop.

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

9. Test for gas soundness.

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

11. Turning either of the temperature control knobs will set the relevant temperature. When the knob is turned the display will alter and show the selected temperature. After a few seconds the display reverts to show the current boiler temperature (Fig. 65).

Pump

Automatic Air

Vent

Pressure Gauge

Screw

bar

Fig. 63

Selector Switch

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Pump

Fig. 65

Fig. 64

Display

Heat Exchanger

Automatic Air Vent

Fig. 62

Reset

bar

11.0 Commissioning

11.2 Checking

1. The gas valve is factory set and the burner pressure cannot be measured as it is altered by suction of the fan and modulates as demand on the boiler alters. The gas supply pressure should be 20mb.

2. If necessary the gas rate may be checked after running the boiler for 10 minutes with any other appliances and pilot lights turned off.

3. Ensure that the integral timer and any external 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.

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

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

/4clockwise

twice and back fully anticlockwise (Fig. 66).

6. The display will now alternate between ‘SF’ and the current boiler temperature and both green LEDs will flash (Figs. 67 & 68).

7. Turn CH temperature control knob fully clockwise. As the knob is turned the display will change from ‘0’ to ‘00’ (Fig. 69) indicating maximum rate, then revert to ‘P’ alternating with the current boiler temperature (Figs 70 & 71).

8. A gas rate measurement may now be made. Approximate values are:-

24 model 2.6m

28 model 3.1m

33 model 3.6 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.

Selector Switch

Display

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Fig. 67

Fig. 68

Fig. 69

Fig. 70

Fig. 71

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Fig. 66

x 2

Reset

bar

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. 71a)

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. 71b).

Constant

Time Pointer

Timed

Off

Rotate to adjust time

Off Position

On Position

Time Pointer

Fig. 71a

Fig. 71b

GRASSLIN

12.0 Completion

12.1 Completion

1. Instruct the user in the operation of the boiler and system 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. 72

Facia Panel

Case Front Panel

Fig. 73

Facia Panel Securing

Screws

Fig. 74

Inner Door

Panel

Fig. 75

Sump

13.0 Servicing

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. 7967-4:2007.

If a suitably calibrated combustion analyser is available it may not be necessary to perform a full strip down of the appliance. Proceed as follows. Check for/inspect:Evidence of leakage of products of combustion Water leaks Heat stress Deterioration such as corrosion Visible condition of seals and joints Flue system and ventilation Condensate drain system Operation at designed maximum heat input

If the above are satisfactory perform a combustion check The CO/CO

ratio must be less than 0.004 and the CO

should be 8.7% ± 0.2 (max. rate) and 8.4% ± 0.2 (min. rate). This can be adjusted - see Section 15.0 - if the readings are incorrect. When correct combustion readings cannot be achieved by adjustment a full strip down must be performed - see below. Carefully check items such as the burner, injector and heat exchanger for blockage or damage, rectifying as necessary. Recheck the combustion. Once satisfactory readings have been achieved and any other defects corrected complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication.

Where no suitable analyser is available a strip down service must be performed as described below.

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

If a full strip-down is to be performed proceed as follows:-

3. Ensure that the boiler is cool.

4. Ensure that both the gas and electrical supplies to the boiler are isolated.

5. 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. 73).

6. Remove the screws securing the inner door panel. Lift the panel slightly to disengage it from the studs on top of the case (Fig. 74).

7. Unscrew the sump from the bottom of the condensate trap assembly (Fig. 75).

8. Remove any deposits from the sump and trap. Clean as necessary and replace the sump.

13.0 Servicing

13.1 Annual Servicing (Cont)

9. Undo the nut on the gas inlet pipe to the venturi (Fig. 77) and pull the sensing pipe off the fan.

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

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

12. Carefully draw the fan, collector and cover assembly forward, being careful to retain the injector in the venturi (Figs. 76 & 77).

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

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

15. Reassemble in reverse order.

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

DHW Filter (Fig. 79)

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

17. Initially check the cold water inlet tap filter.

18. Turn the tap off and draw off from a hot tap. Undo the blanking cap and remove the threaded bush (Fig. 78).

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

20. Pull off the Hall Effect sensor. Undo the restricter from the inlet/return manifold (Fig. 79).

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

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

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

Fig. 76

Cold Water

Inlet Tap

Blanking

Cap

Threaded

Bush

Fig. 78

Fig. 77

Hall Effect

Sensor

Hydraulic Inlet

Assembly

Fig. 79

Gas Inlet Pipe

Venturi

Injector

Restricter

Fan, Collector and Cover

Assembly

Filter

Electrode

Leads

4 ± 0.5

10 ± 1

7.5 ± 1

Electrode Position

Viewing Window

Burner

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 13.1 “Annual Servicing” for removal of case panel, door etc.

14.1 Igniter (Fig. 80)

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. 81)

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 gasket and replace if necessary. Reassemble in reverse order.

Fig. 80

Igniter

Igniter Feed

Plug

Electrode

Leads

Bracket

Fig. 81

Spark

Electrode

Sensing

Electrode

Leads

14.0 Changing Components

Cover

Gas Inlet

Fan

Venturi

Injector

Collector

Burner Gasket

When fitting the venturi

ensure that the arrow is

pointing forward

Fig. 82

Fig. 83

Gas Inlet Pipe

Venturi

Injector

Fig. 84

14.3 Fan (Fig. 83)

1. Undo the nut on the gas inlet pipe to the venturi (Fig. 83) 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 cover (33 models) or extension piece (24 & 28 models).

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. 82)

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. 84).

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. 82)

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

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

14.0 Changing Components

Fig. 85

Cover

Burner

Gasket

Extension Piece

(24 & 28 models)

Collector

Venturi

Heat

Exchanger

Rear

Insulation

Cover

Insulation

Seal

Collector

Spark

Electrode

Sensing

Electrode

Leads

Venturi

Fig. 86

14.6 Burner (Fig. 85)

1. Undo the screws securing the collector to the cover and venturi. (On 24 & 28 models there is an extension piece fitted to the cover, remove this also).

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. 86)

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. The rear insulation is retained by a screw and large washer, remove these and draw the insulation out of the heat exchanger.

6. Examine the cover seal and replace if necessary.

14.0 Changing Components

Central Heating

Temperature Sensor

Safety Thermostat

Flow Pipe

Fig. 88

DHW Temperature

Sensor

Fig. 89

Plate Heat Exchanger

Pressure Sensor

Flue/Heat Exchanger

Thermostat Sensor

Electrical

Plug

Fig. 87

14.8 Flue/Heat Exchanger Thermostat Sensor

(Fig. 87)

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. 89)

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. 88)

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. 88)

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. 89)

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.

14.0 Changing Components

14.11 Heat Exchanger Automatic Air Vent (Fig. 90)

1. Drain the boiler 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, transferring the grommet to the new vent.

4. Ensure that the grommet is is sealed correctly to the boiler top panel.

14.12 Pump - Head Only (Fig. 91)

1. Drain the boiler 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. 92).

4. Reassemble in reverse order.

14.13 Pump - Complete (Fig. 93)

1. Drain the boiler 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.

14.14 Automatic Air Vent (Fig. 93)

1. Drain the boiler 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. 91

Fig. 93

Fig. 92

Pump Wiring

Cover

Pump Wiring

Cover

Heat Exchanger

Air Vent

Grommet

Fig. 90

14.0 Changing Components

14.15 Pressure Gauge (Figs. 94 & 95)

1. Drain the boiler 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.

14.16

Hall Effect Sensor (Fig. 96)

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.

14.17 Pressure Relief Valve (Fig. 97)

1. Drain the boiler 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. 95

Fig. 94

Pressure Relief Valve

Grub Screw

‘O’ ring seal

Discharge Pipe

Fig. 97

Hall Effect

Sensor

Hydraulic Inlet

Assembly

Fig. 96

14.0 Changing Components

14.18 Plate Heat Exchanger (Fig. 98)

1. Drain the boiler primary circuit and remove the gas valve as described in section 13.22.

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.

14.19 Diverter Valve - Motor Unit & Assembly

(Figs. 99 & 100)

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. Remove the spring clip retaining the bypass pipe to the rear of the assembly and under the flow pipe nut at the left hand side.

6. 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.

7. 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.

Plate Heat Exchanger

Rubber Seal

Fig. 98

Motor Unit

Multi-pin Plug

Retaining Clip

Valve

Assembly

Spring Clip

Bypass Pipe

Securing Screw

Fig. 99

Fig. 100

LH Location Stud

Pressure Sensor

14.0 Changing Components

14.20 P.C.B. (Fig. 102)

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. 101).

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.

14.21 Selector Switch (Fig. 102)

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. 101).

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.

Control Box Cover

P.C.B.

Selector

Switch

Facia

Selector Switch Knob

Temperature Control Knobs

Fig. 101

Fig. 102

Drive Pins

Gas Valve

Valve

Inlet Pipe

Gas Feed

Elbow

Fig. 103

Ignition Lead

Expansion Vessel

Boiler Chassis

Lock Nut

Fig. 104

Retaining Bracket

Sensing Pipe

Venturi Inlet

Pipe

Outlet Adaptor

14.0 Changing Components

14.23

Gas Valve (Fig. 103)

IMPORTANT: After replacing the valve the CO2must be checked and adjusted as detailed in Section 15.0 Combustion Check. Only change the valve if a suitable calibrated combustion analyser is available.

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

2. Remove the screws securing the inlet pipe flange to the boiler bottom panel.

3. Pull off the earth lead and sensing pipe.

4. Undo the nut on the venturi inlet pipe and slacken the nut on the venturi. Ease the pipe aside and remove the gas valve.

5. Remove the outlet adaptor and inlet pipe and transfer them to the new valve. Examine the ‘O’ ring seals, replace if necessary.

6. Reassemble in reverse order.

NOTE: To assist the boiler to light prior to final setting, use a suitable hexagon key to wind out the Gas/Air adjustment screw until it is flush with the valve body, then turn the screw 4 full turns clockwise (Fig. 103a). If the boiler will not light, or the correct CO

cannot be achieved

contact the ‘heateam’ technical helpline.

14.24 Expansion Vessel (Fig. 104)

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.

Fig. 103a

Gas/Air

Adjustment Screw

15.0 Combustion Check

15.1 Checking the CO

IMPORTANT: The CO2 must only be checked and adjusted if a suitable calibrated combustion analyser is available.

1. The combustion (CO

) may be checked using a suitably calibrated analyser after running the boiler for several minutes.

2. To do this it is necessary to set the boiler to ‘Calibration Mode’.

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

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

/4clockwise

twice and back fully anticlockwise (Fig. 105).

5. The display will now alternate between ‘SF’ and the current boiler temperature and both green LEDs will flash (Figs. 106 & 107).

6. Turn the CH temperature knob fully clockwise. As the knob is turned the display will change, indicating the fan speed.

7. The display will show ‘00’, indicating maximum rate, then revert to ‘P ‘ alternating with the current boiler temperature (Figs 108, 109 & 110).

8. Remove the plug from the flue adaptor test point. Insert the analyser probe and allow time for the reading to settle (Fig. 111).

The CO

should be 8.7% ± 0.2

9. It is possible to alter the CO

by adjustment of the gas valve. Remove the plastic cover from the ‘Max Rate’ adjustment screw. At maximum rate the ‘Max. Rate’ adjustment screw should be turned, using a suitable hexagon key, until the correct reading is obtained (Fig. 112). Turning clockwise will reduce the CO

. Anticlockwise will

increase the CO

10. The CO2must then be checked at minimum rate. Turn the CH temperature knob fully anticlockwise. 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.

11. With the boiler on minimum, the ‘Min. Rate’ adjustment screw must be altered, using a suitable hexagon key, after removing the cap (Fig. 112). If the CO

is reset at either boiler rate it must be rechecked at the other rate and also adjusted if required.

12. 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 DHW knob.

Selector Switch

Display

Central Heating

Temperature Control

Domestic Hot Water

Temperature Control

Fig. 106

Fig. 107

Fig. 108

Fig. 109 Fig. 110

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Fig. 105

x 2

Fig. 111

Max Rate

Adjustment Screw

(cover removed)

Min Rate

Adjustment Screw

(cap fitted)

Gas Valve

Fig. 112

Flue Adaptor Test

Point

Plug

Analyser Probe

Reset

bar

16.0 Electrical

16.1 Illustrated Wiring Diagram

Water Pressure Switch

DHW NTC Sensor

X501

Hall Effect

Sensor

Control PCB

Central Heating NTC Sensor

X400

54321

9876

X2 X3

Overheat Stat

910 8 7 6

1212 3344

54321

Flue Sensor

X401

556789

1234

g/y

Fan

Timer

Link

Mains Input Cable

Flame

Sensing

Electrode

g/y

Spark Generator

Ignition Electrode

Pump

Diverter Valve

Gas Valve

br bk b w

- brown

- black

- blue

- white

- green

- green / yellow

g/y

- red

17.0 Short Parts List

Short Parts List

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

326 Fan 5121447

426 Motor 3way Valve 248733

315 Igniter Electrode 5114702

316 Sensing Electrode 5114703

422 Gas Valve 5119647

404 Hall Effect Sensor 5114767

313 Burner 24 5122149

Burner 28 5114697

Burner 33 5114698

419 Water Pressure Switch 5114748

400 Plate Heat Exchanger 24 248048

Plate Heat Exchanger 28/33 5114708

415 Pump 248042

421 NTC Sensor 5114725

420 Overheat Thermostat 5114729

504 Pressure Gauge 248090

503 PCB 24 5121862

PCB 28 5120218

PCB 33 5120219

306

426

315

316

311

422

624

419

400

415

302

421

420

503

504

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 or incorrect 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

18.0 Fault Finding

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

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 if fitted) 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 125 or 193 flashing

Ensure that primary

circulation is OK & that

there is no blockage

YES

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

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 5 & 7

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

18.0 Fault Finding

E20 or E50 - Temperature sensors faulty. Cold resistance approximately 10kΩ @ 25° C (DHW and CH sensors) 20kΩ @ 25° C (Flue sensor) (resistance reduces with increase in temp.)

E28 - Incorrect PCB fitted

Replace sensor or PCB (E28)

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

4 ± 0.5

10 ± 1

7.5 ± 1

Electrode Position

Viewing Window

Burner

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 μA

Replace PCB

YES

Replace flame sensing electrode

Check the gas supply pressure:

For Natural Gas greater than

10 - 11 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

1 1

1.0 Introduction

CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes

TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT

TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER

COMBI BOILER

HEATING ZONE VALVES FITTED NOT REQUIRED

HOT WATER ZONE VALVES FITTED NOT REQUIRED

THERMOSTATIC RADIATOR VALVES FITTED

AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS?

THE SYSTEM CLEANER USED

THE INHIBITOR USED

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

GAS RATE ft3/hr

BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

CENTRAL HEATING FLOW TEMPERATURE °C

CENTRAL HEATING RETURN TEMPERATURE °C

FOR COMBINATION BOILERS ONLY

HAS A WATER SCALE REDUCER BEEN FITTED? YES NO

WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE ft3/hr

MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

COLD WATER INLET TEMPERATURE °C

HOT WATER OUTLET TEMPERATURE °C

WATER FLOW RATE

lts/min

FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS? YES

FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING

THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS

THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS

IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2 RATIO READING? N/A YES CO/CO2 RATIO

THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER

THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER

m3/hr

/hr

COMMISSIONING ENG’S NAME PRINT CORGI ID No.

SIGN DATE

BOILER SERIAL No. NOTIFICATION No.

BENCHMARK No.

GAS BOILER COMMISSIONING CHECKLIST

COLLECTIVE MARK

N/A

5116282

SERVICE 1

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 2

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 3

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 4

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 5

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 6

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 7

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 8

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 9

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 10

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE INTERVAL RECORD

It is recommended that your heating system is serviced regularly

and that you complete the appropriate Service Interval Record Below.

Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service

as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls

UK Comp No5116282 - Iss 7 - 4/08

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.

IT Comp No 925.659.2

POTTERTON

A Trading Division of Baxi Heating UK Ltd (3879156) A Division of Baxi Group

Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 08706 017 017 Technical Enquiries 08706 049 049 Website www.potterton.co.uk e&oe

Baxi Potterton Gold HE A Range User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual