Baxi Potterton Heatmax Combi HE User Manual

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Installation & Service Instructions

Heatmax

Combi HE

Range

Condensing

Combination Boiler

These instructions include the Benchmark Commissioning

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

Natural Gas

Potterton Heatmax Combi 24 HE

47-393-27

G.C.N

Potterton Heatmax Combi 28 HE

G.C.No47-393-28

Potterton Heatmax Combi 33 HE

G.C.No47-393-29

Building Regulations and the Benchmark Commissioning Checklist

Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly. Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1 January 2006.

The Health & Safety Executive operates the ‘Gas Safe Register’, a self-certification scheme for gas heating appliances.

These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook (which was then left on site with the customer).

With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn. However, a similar document in the form of a commissioning checklist and service interval record is incorporated at the back of these instructions.

The Benchmark Scheme

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

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

© Baxi Heating UK Ltd 2012 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner, except for permitted fair dealing under Copyrights, Designs and Patents Act 1988.

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

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

Full acknowledgement of author and source must be given.

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

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.

0086

ISO 9001

FM 00866

Choose Building

Regulations Notification

Route

Installer Notification Guidelines

Competent Person's

Self Certification Scheme

Install and Commission this appliance to manufacturer's

instructions

Complete the

Benchmark Checklist

If you notify via the ‘Gas Safe

the Building Regulations

certificate on members’ behalf

Building Control

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact a government approved

inspector

Install and Commission this appliance to manufacturer's

instructions

Scheme Members only

Call ‘Gas Safe Register’ on:

0800 408 5577

or log onto:

www.gassaferegister.co.uk

within 10 days

You must ensure that the

certificate number issued by

the ‘Gas Safe Register’ is written

onto the Benchmark Checklist

‘Gas Safe Register’ will issue a

Building Regulations Compliance

Certificate to the property owner

and inform the relevant LABC

Complete the

Benchmark Checklist

LABC will record the data

and will issue a

certificate of compliance

IMPORTANT - Installation, Commissioning, Service & Repair

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

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

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

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

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

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

Legislation

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

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

In GB, the installation must be carried out by a Gas Safe Registered Installer. It must be carried out in accordance with the relevant requirements of the:

• Gas Safety (Installation & Use) Regulations.

• The appropriate Building Regulations either The Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland).

• The Water Fittings Regulations or Water Byelaws in Scotland.

• The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent Person and installed in accordance with the current edition of I.S. 813 ‘Domestic Gas Installations’, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.

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

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

Regulations 1993 N

3083” and is deemed to meet the requirements of Directive 92/42/EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by: Notified Body 0085.

Product/Production certified by: Notified Body 0086.

For GB/IE only.

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

Codes of Practice - refer to the most recent version

In GB the following Codes of Practice apply: Standard Scope

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

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

heating systems. BS 6798 Installation of gas fired hot water boilers. BS 5440 Part 1 Flues. BS 5440 Part 2 Ventilation. BS 7074 Expansion vessels and ancillary equipment for

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

central heating systems.

In IE the following Codes of Practice apply: Standard Scope

I.S. 813 Domestic Gas Installations. The following standards give valuable additional information; BS 5546 Installation of hot water supplies for domestic

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

heating systems. BS 7074 Expansion vessels and ancillary equipment for

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

central heating systems.

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

Section Page

1.0 Introduction 7

2.0 General Layout 8

3.0 Appliance Operation 9

4.0 Technical Data 10

5.0 Dimensions and Fixings 11

6.0 System Details 12

7.0 Site Requirements 15

8.0 Flue Options 21

9.0 Plume Displacement 25

10.0 Installation 29

11.0 Commissioning 34

12.0 Completion 36

13.0 Servicing 37

14.0 Changing Components 39

15.0 Setting the Gas Valve 48

16.0 Electrical 49

17.0 Short Parts List 50

18.0 Fault Finding 51

19.0 Pages for Notes 57

Benchmark Checklist 58

Case Front Panel

1.0 Introduction

1.1 Description

1. The Potterton Heatmax Combi HE 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 data badge gives details of the model, serial number and Gas Council number and is situated on the inner door panel or the control box. It is visible when the case front panel is removed (Fig. 1).

Control Box

Facia Door

Fig. 1

Data Badge

Information Label

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

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

8. The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit, part no. 5118489 .

9. All systems must be thoroughly flushed and treated with

inhibitor (see section 6.2).

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

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

1.2 Optional Extras

Integral timers, RF room thermostats, wall ‘stand off’ kits etc. are available as optional extras.

1.3 Contents of Pack

The pack contains:-

• Boiler

• Wall Plate (including taps)

• Set of Pipe Connections

• Template & ‘Quick Fit’ Guide

• Literature Pack

• Filling Loop

2.0 General Layout

2.1 Layout

1. Expansion Vessel

2. Automatic Air Vent (Pump)

3. DHW Plate Heat Exchanger / Automatic Bypass

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 Knob

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. Selector Switch

Reset

bar

3.0 Appliance Operation

Central Heating Circuit

Fig. 2

Key

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

Domestic Hot Water Circuit

5 6

1213141516

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

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 (if fitted) will require resetting once the selector switch is set to either Position ( ) or Position ( ).

Fig. 3

3.3 Frost Protection Mode

5 6

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

3.4 Pump Protection

1. With the selector switch (see Section 2.1) in either the

1213141516

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.

4.0 Technical Data

4.1 Heatmax Combi 24, 28 & 33

Appliance Type C

Appliance Category CAT I 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 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 Output CH (Non-Condensing)

Max Min 24 model kW 20 6.8 28 model kW 24 8.7 33 model kW 28 9.4

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

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 2.6 28 model m3/h 3.1

33 model m

/h 3.6

SEDBUK Declaration

SAP 2005 Seasonal Efficiency for all

models is 91.1%

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of

dwellings. The test data from which it has been

calculated has been certified by 0087.

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

Inlet Pressure (Natural Gas - G20)

mbar 20

Injector (Natural Gas - G20)

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

Electrical Supply 230V~ 50H

(Appliance must be connected to an

earthed supply)

Power Consumption

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

Electrical Protection

IPX5D

NOxClass 5

Central Heating Primary Circuit Pressures

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

DHW Circuit bar Pressures

Max Operating 8 Min Operating 0.15

Flow Rates (24) (28) (33)

External Fuse Rating 3A Internal Fuse Rating F2L

Condensate Drain

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

Flue Terminal Diameter 100mm Dimensions Projection 125mm

Connections copper tails

Gas Supply - 22mm Central Heating Flow - 22mm Central Heating Return - 22mm

DHW Flow Rate @ 30o CRise 11.43 13.3 15.7

DHW Flow Rate @ 35o CRise 9.8 11.5 13.5

Min Working DHW Flow Rate 2 2 2

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

l/min l/min l/min

Cold Water Mains Inlet - 15mm DHW Flow - 15mm Pressure Relief Discharge - 15mm

Outercase Dimensions

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

Clearances

Above Casing 200 mm Min Below Casing 150 mm Min* Front 450 mm Min(For Servicing) Front 5 mm Min (In Operation) L.H. Side 5 mm Min R.H. Side 5 mm Min

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

Weights (kg)

(24/28) (33)

Packaged Boiler Carton 48.6 51 Installation Lift Weight 43.6 46

5.5 5

4.5 4

3.5 3

2.5 2

Metre (wg)

1.5 1

0.5 0

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

Temperatures

C.H. Flow Temp (adjustable)

25°C to 80°C max (± 5°C)

D.H.W. Flow Temp

(adjustable)

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

Pump - Available Head

200 400 600 800 1000 1200

Flow Rate (l/h)

At Least 1.5°

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

5.0 Dimensions and Fixings

Dimensions

A 780mm

B 345mm C 450mm

ØD

360° Orientation

D 116mm Ø Min. E 185mm

(207mm for 80/125mm flue systems)

F 145mm G 131mm H 180mm

Tube Ø 100mm

Tap Rail

6.0 System Details

6.1 Information

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

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

1. The Potterton Heatmax Combi HE 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, Sentinel X300 or X400 or Fernox F3. 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. Sentinel X100 and Fernox MB-1 which should be used following the inhibitor manufacturer’s instructions.

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

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

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

6.4 System Control

1. The boiler is designed for use in a heating system that incorporates external controls, i.e. a minimum of a timer device.

2. Suitable timer kits are available as optional extras.

3. For optimum operating conditions and maximum economy the fitting of a programmable room thermostat is recommended.

6.0 System Details

6.5 System Filling and Pressurising

Fig. 4

Filling Loop Connections

Stop Valve

DHW Mains Inlet

Fig. 5

Double Check Valve

Temporary Hose

Stop Valve

CH Return

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

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. 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”.

Safety Pressure Relief Valve

Fig. 6

Discharge Pipe

6.7 Safety Pressure Relief Valve (Fig. 6)

1. The safety 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).

Other Tap Outlets

Expansion Vessel

Boiler

6.0 System Details

6.8 Domestic Hot Water Circuit (Fig. 7)

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

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

Fig. 7

Check Valve*

Pressure Reducer Valve*

Stop Tap

To Hot Taps

* See 6.8 for instances when these items may be required

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

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

5. 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.

7.0 Site Requirements

5mm Min

Fig. 8

450mm

5mm Min

200mm Min

(300mm Min if

using 80/125mm

flueing system)

780mm

150mm Min*

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).

450mm Min

For Servicing

Purposes

At Least 1.5°

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

7.2 Clearances (Figs. 8 & 9)

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

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

5mm Min

In Operation

Fig. 9

Gas Service Cock

Fig. 10

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).

Fig. A

Zone 1

Zone 0

Zone 1

Zone 0

Window Recess

Zone 2

Window Recess

Zone 2

0.6 m

In GB Only

Window Recess Zone 2

Zone 2

0.6 m

2.25 m

Ceiling

Outside Zones

7.5 Electrical Supply

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

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

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

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

7.6 Bath & Shower Rooms

1. If the boiler is fitted in a room containing a bath or shower and NOT FITTEDwith any optional integral timer or thermostat, it can be fitted in zone 2, (Figs. A & B shows zone dimensions for a bathtub. For other examples refer to the Current I.E.E. Wiring Regulations) reference must be made to the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of I.S. 813 “Domestic Gas Installations” and the current ETCI rules.

Fig. B

In GB Only

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

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

21.5mm

50mm per metre of pipe run

2.5° Minimum fall

32mm

i) Termination to an internal soil and

Insulation

vent pipe

7.0 Site Requirements

7.7 Condensate Drain

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

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

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

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

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

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

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

/4in) plastic

Sink

450mm min*

Boiler

50mm per metre of pipe run

2.5° Minimum fall

ii) External termination via internal discharge branch

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

e.g sink waste - downstream*

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

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

the Building Regulations give further detailed guidance.

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

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

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

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

internally and preferably be less than 3 metres.

7. Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe.

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

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

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

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

7.0 Site Requirements

Boiler

50mm per metre of pipe run

2.5° Minimum fall

iv) Termination to a purpose made soakaway

Boiler

iii) Termination to a drain or gully

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

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

500mm min

7.7 Condensate Drain (cont.)

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

50mm per metre of pipe run

2.5° Minimum fall

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

v) pumped into an internal discharge branch

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

50mm per metre of pipe run

Sink

2.5° Minimum fall

Basement or similar (heated)

Boiler

Condensate Pump

vi) pumped into an external soil & vent pipe

50mm per metre of pipe run

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

7.0 Site Requirements

7.7 Condensate Drain (cont.)

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

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

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

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

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

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

Unheated Location (e.g. Garage)

Boiler

2.5° Minimum fall

Basement or similar (heated)

Condensate Pump

vii) to a drain or gully with extended

external run & trace heating

The ‘Trace Heating’ element must be installed in accordance

Boiler

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

50mm per metre of pipe run

2.5° Minimum fall

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

300 min

Terminal Assembly

Top View Rear Flue

Property Boundary Line

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

A1Directly below an opening, air brick, opening

windows, etc. 300 B1Above an opening, air brick, opening window etc. 300 C1Horizontally to an opening, air brick, opening window etc. 300 D2Below gutters, soil pipes or drain pipes. 25 (75) E2Below eaves. 25 (200)

Below balconies or car port roof. 25 (200)

F G2From a vertical drain pipe or soil pipe. 25 (150) H2From an internal or external corner. 25 (300) I Above ground, roof or balcony level. 300 J From a surface or boundary line facing a terminal. 600 K From a terminal facing a terminal (Horizontal flue). 1200

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

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

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

Only ONE 25mm clearance is allowed per installation. If one of the dimensions D, E, F, G or H is 25mm then the remainder MUSTbe as B.S.5440-1.

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

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.

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

IMPORTANT:

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

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

Fig. 17

Plume Displacement Kit

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

Air Inlet

J,K

Opening Window or Door

150mm MIN.

J,K

Fig. 18a

Likely flue positions requiring a flue terminal guard

Fig. 18

Horizontal Flues

8.0 Flue Options

8.1 Horizontal Flue Systems

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

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

each fitting to aid assembly.

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

Horizontal Concentric 10 metres 20 metres

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

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

135° bend 0.5 metres 93° bend 1.0 metres

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

in any equivalent length calculations.

6. The illustrations opposite show examples of permissible

flue systems.

Plume Displacement Kit 60 /100 Ø

1M Extensions, 45° & 93° bends are

also available - see Section 9.0

NOTE: Horizontal flue pipes should always be installed with a fall of at least 1.5° from the terminal to allow condensate to run back to the boiler.

This bend is equivalent to 1 metre

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

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

Total equivalent length = A+B+C+2x90°Bends

8.0 Flue Options

Vertical Flues

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.

8.2 Vertical Flue Systems

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

Vertical Concentric 10 metres 20 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

The elbow supplied with the standard horizontal flue kit is not included in any equivalent length calculations

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

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

Roof

Terminal

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

This bend is equivalent to 1 metre

8.0 Flue Options

Key Accessory Size Code No

FLUE GROUP A Concentric Flue System 100mm diameter

8.3 Flue Accessories

A Horizontal Flue Terminal (inc. elbow) 5118489 A2 Telescopic Flue (inc. elbow) 315-500mm5118069 A3 Telescopic Internal Flue Kit 315-500mm5119654 B Flue Extension 1000mm 5111074 C Flue Bend 93° 5111075 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 G

Concentric Flue System 80/125mm diameter

A4 Horizontal Flue Kit 5118580 B Straight Extension Kit 1000mm 5118584

K,K1

D Bend Kit (pair) 135° 5118597 C Bend 91.5° 5118588 U Pipe support 125mm 5118610

FLUE GROUP A & 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

Cut the same amount off the Air Duct & Flue Duct

Air Duct

Flue Duct

Approx

1425mm

8.0 Flue Options

8.6 For Roof Terminals

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

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

100mm

685mm

Fig. 19

Push Fit Adaptor

Flue Deflector

Fig. 20

8.7 Flue Dimensions

The standard horizontal flue kit allows for flue 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. Push the flue deflector over the terminal end and rotate to the optimum angle for deflecting plume. Secure the deflector to the terminal with screws provided.

Fig. 21

93° Elbow/Plume Outlet Assembly

9.0 Plume Displacement

Fig. 22

45°

0.9 metres

45°

O Ring

Adaptor

O Ring

60/100Ø Concentric Flue

Outlet must be at least 45° from wall face

60Ø Support Bracket

60Ø Exhaust Flue Pipe

60Ø Support Bracket

Flexible Flue Trim

‘Jubilee’ Clip

Fig. 23

‘Peak’ Uppermost

Elbow

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.

Fig. 24

Air Inlet at Bottom

500mm Min.

Fig. 25

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.

9.0 Plume Displacement

60 Ø Exhaust (metres) X

28/33

34 65798

Concentric 60/100 Flue (metres) Y

Example 1 Flue Lengths - Not Permissible

60 Ø Exhaust (metres) X

Example 3 Flue Lengths - OK

60 Ø Exhaust (metres) X

28/33

34 65798

Concentric 60/100 Flue (metres) Y

Example 2 Flue Lengths - OK

28/33

34 65798

Concentric 60/100 Flue (metres) Y

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 equivalences must be accounted for i.e. 93° bends are equal to 1 metre, each 45° bend to 0.5 metres.

60Ø Exhaust

Concentric 60/100 Flue

Fig. 26

Additional Accessories

A - 93° Elbow 5121369 B - 45° Elbow (Pair) 5121370 C - 1 metre 60Ø Extension 5121368

45° Elbow

93° Elbow

Concentric Flue

Fig. 27

Support Bracket

1 metre Extension

1 metre supplied in kit

Flue Length - Worked Example Potterton Heatmax 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.

9.0 Plume Displacement

30mm

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°.

Spigot

Fig. 28

Flue Trim

Min. 2 metres

2. When completed the terminal must be at least 2 metres above ground level (Fig. 28).

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. 29, 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.

Fig. 29

Fig. 31

Fig. 32

50mm

30mm

Position of ‘Jubilee’ Clip screw

Adaptor

Fig. 30

9. The 60Ø exhaust can now be fitted. Slide the adaptor over the plain end of the 60Ø exhaust (Fig. 31) 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. 30. 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. 32. 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. 33).

Fig. 33

9.0 Plume Displacement

30mm

Plume Outlet

Fig. 34

Fig. 35

500mm Min.

Elbow

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).

200mm Min.

Fig. 37

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.

Outlet Spigot

70°

Concentric Flue Length (shown end-on)

Fig. 38

Fig. 39

Fig. 40

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).

Flushing Tube

Central Heating Return

Fig. 41

Fig. 42

145mm

For Side Flue Exit

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 suitable plugs and screws. Secure the plate to the wall.

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).

2. Flush thoroughly (see System Details, Section 6.1).

Fig. 43

Wall Plate

Sealing Washers

10.0 Installation

10.3 Fitting The Boiler

1. Remove the sealing caps from the boiler connections.

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

2. Lift the boiler as indicated by the shaded areas. The boiler

should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig. 43) (see Safe Manual Handling page 5).

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 connections.

4. Tighten all the connections and fit the filling loop.

Suggested Lifting Points shown as shaded area

Pressure Relief Valve

Remove Sealing Caps from under the Boiler after lifting into position

Fig. 44

Safety Pressure

Relief

10.4 Fitting the Safety Pressure Relief

Discharge Pipe (Fig. 44)

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.

10.5 Condensate Drain (see section 7.7)

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

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

2. The connection will accept 21.5mm (

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

Wall Thickness

100mm 685mm

Fig. 45

10.0 Installation

10.6 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. 45).

2. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (Fig. 47). The elbow is fully engaged when there is a distance of 20mm from the adaptor to the indicator line (Fig. 46).

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. 48).

(X)

Apply Lubricant for ease of assembly.

Ensure Elbow is fully engaged into Boiler Adaptor

Flue Elbow

Fig. 47

Adaptor

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. 49). Carefully cut the waste material from the flue, ensuring that the ducts are square and free from burrs.

(X)

Fig. 48

Waste

Wall Thickness

Flue

Fig. 49

Inner Flue Support Bracket

10.0 Installation

10.6 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.

Apply Lubricant for ease of assembly.

Ensure Flue is fully engaged into Flue Elbow

Fig. 50

Slots at bottom

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. 50).

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. 51).

10. Ensure that the terminal is positioned with the slots to the bottom (Fig. 52).

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).

Fig. 52

Cut End

25mm

Tape

Apply Lubricant for ease of assembly.

Ensure Extension is fully engaged into Boiler Adaptor

Fig. 51

Extension

Fig. 53

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. 53).

15. Engage the extension into the adaptor up to this position (Fig. 54 ). Once the installation of the flue is complete and all support brackets are securely in place remove the tape.

Adaptor

Fig. 54

Terminal Block Cover

Fig. 55

10.0 Installation

10.7 Making The Electrical Connections

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. 55).

3. Undo the terminal block cover securing screw and remove the cover (Fig. 55).

4. Slacken the unused cable clamp on the LH side of the boiler chassis (Fig. 56). Insert the external control wiring through the clamp and route it to the terminal block.

Fig. 56

Cable Clamp

Fig. 57

Fused Spur

Facia Panel

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.

Room ‘Stat

6. Remove the link between terminals 1 & 2. The 230V supply at terminal 2 must be connected to the thermostat. The switched output from the thermostat must be connected to terminal 1 (Fig. 57). If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Fig. 57.

230V

g/y

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.

Frost Thermostat

Room ‘Stat

230V

10.8 Preliminary Electrical Checks

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

NOTE: The 230V switched signal for external controls (Frost Stat - Room Stat - Timer) must always be taken from terminal 2 at the boiler. Live, Neutral and Earth to power these controls must be taken from the Fused Spur.

External Clock

230V

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

g/y

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

Screw

bar

11.0 Commissioning

11.1 Commissioning the Boiler

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

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

3. Open the mains water supply to the boiler.

Fig. 59

Selector Switch

Reset

Fig. 61

Automatic Air

Pump

Display

Central Heating

Temperature Control

Pump

Vent

Fig. 60

bar

Domestic Hot Water Temperature Control

Pressure Gauge

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

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

6. Open the screw on the automatic air vent on the pump body (Fig. 59).

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

8. Pressurise the system to 1.5 bar (Fig. 60) then close and disconnect the filling loop.

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

10. Test for gas tight ness.

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

IMPORTANT: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type specified on the appliance data plate. No measurement of the combustion is necessary. Do not adjust the air/gas ratio valve.

12. Having checked:

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

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

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

Proceed to put the boiler into operation as follows:

Central Heating

Temperature Control

Selector Switch

Display

Fig. 62

Domestic Hot Water

Temperature Control

x 2

11.0 Commissioning

11.2 Check the Operational (Working) Gas Inlet

Pressure

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

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

Reset

Gas Pressure

Test Point

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Gas Valve

Fig. 62a

3. Turn both temperature control knobs fully anticlockwise,

then quickly turn the DHW temperature knob

bar

twice and back fully anticlockwise (Fig. 62).

4. The display will now alternate between ‘SF’ and the current

/4clockwise

boiler temperature and both green LEDs will flash (Figs. 63 &

64).

5. Turn CH temperature control knob fully clockwise. As the knob is turned the display will change from ‘0’ to ‘00’ (Fig. 65) indicating maximum rate, then revert to ‘P’ alternating with the current boiler temperature (Figs 66 & 67).

6. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point (Fig. 62a) is in accordance with B.S. 6798 & B.S. 6891.

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

Measure the Gas Rate

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

24 model 2.61 m 28 model 3.1 m 33 model 3.6 m

Fig. 63

Fig. 66

Fig. 65

Fig. 67

Fig. 64

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

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

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

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

12.0 Completion

12.1 Completion

Case Front Panel

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.

Facia Panel

Fig. 68

13.0 Ser vicing

13 .1 Annual Servicing

Case Front Panel

Fig. 69

Facia Panel Securing

Screws

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

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

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

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

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

•The operational gas inlet pressure as described in Section

11.2.1 to 11.2.7 and the gas rate as described in 11.2.8.

•The combustion performance as described in ‘Check the

Combustion Performance’ (13.1.4 to 13.1.6 below).

3. Competence to carry out Checking Combustion

Performance

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

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

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

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

Inner Door

Panel

Fig. 70

Fig. 71

Sump

Check the Combustion Performance (CO/CO

ratio)

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

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

analyser probe and obtain the CO/CO

ratio. This must be

less than 0.004.

6. If the combustion reading (CO/CO

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

•Perform the ‘Annual Servicing - Inspection’ (Section 13.2) &

re-check

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

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

13.2 Annual Servicing - Inspection

1. Ensure that the boiler is cool.

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

boiler are isolated.

3. Slacken the screws securing the facia panel. Lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel, allowing the facia to hinge down (Fig. 69).

4. Remove the screws securing the inner door panel. Lift the panel slightly to disengage it from the studs on top of the case (Fig. 70).

5. Unscrew the sump from the bottom of the condensate trap assembly (Fig. 71) and remove any deposits from the sump and trap. Clean as necessary and replace the sump.

0.5 ±

13.0 Ser vicing

13.2 Annual Servicing - Inspection (Cont)

6. Undo the nut on the gas inlet pipe to the venturi (Fig. 73) and pull the sensing pipe off the fan.

Electrode

Leads

Sensing Electrode

Fig. 72

7.5

Spark Ignition Electrode

the fan electrical plugs.

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

9. Carefully draw the fan, collector and cover assembly forward, being careful to retain the injector in the venturi (Figs. 72 & 73).

Fan, Collector and Cover

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

Assembly

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

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

12. Reassemble in reverse order.

NOTE: The sensing pipe must be reconnected to the

Venturi

Injector

fan, not the venturi.

DHW Filter (Fig. 75)

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

Fig. 73

Restricter

Hall Effect

Sensor

Filter

Gas Inlet Pipe

Fig. 75

Threaded

Bush

Fig. 74

14. Initially check the cold water inlet tap filter.

15. Turn the tap off and draw off from a hot tap. Undo the blanking cap and remove the threaded bush (Fig. 74).

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

17. Pull off the hall effect sensor. Undo the restrictor from the inlet/return manifold (Fig. 75).

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

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

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

Hydraulic Inlet

Assembly

Blanking

Cap

Cold Water

Inlet Tap

14.0 Changing Components

Electrode

Leads

Fig. 76

Bracket

Igniter

Igniter Feed

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.

Plug

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

14.1 Igniter (Fig. 76)

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.

Spark

Electrode

14.2 Spark and Sensing Electrodes (Fig. 77)

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.

Electrode

Leads

Fig. 77

Sensing

Electrode

Venturi

Injector

14.0 Changing Components

14.3 Fan (Fig. 79)

1. Undo the nut on the gas inlet pipe to the venturi (Fig. 79) 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.

Fig. 79

Burner Gasket

Collector

Gas Inlet Pipe

Injector

Fig. 78

Cover

Venturi

Fan

14.4 Venturi (Fig. 78)

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.

Gas Inlet

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

14.5 Injector (Fig. 78)

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

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

Fig. 80

When fitting the venturi

ensure that the arrow is

pointing forward

Extension Piece

(not on 33 models)

Gasket

Burner

Cover

14.0 Changing Components

14.6 Burner (Fig. 81)

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.

Fig. 81

Collector

Venturi

4. Reassemble in reverse order.

14.7 Insulation (Fig. 82)

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.

Spark

Electrode

Leads

Heat

Exchanger

Rear

Insulation

Venturi

Cover

Insulation

Seal

Fig. 82

Collector

Sensing

Electrode

Electrical

Plug

Flue/Heat Exchanger

Thermostat Sensor

14.0 Changing Components

14.8 Flue/Heat Exchanger Thermostat Sensor

(Fig. 83)

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

2. Turn the sensor 90 bayonet connection.

3. Reassemble in reverse order.

anticlockwise to remove - it is a

Fig. 83

Flow Pipe

Central Heating

Temperature Sensor

14.9 Water Pressure Sensor (Fig. 85)

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. 84)

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.

Fig. 84

Pressure Sensor

Fig. 85

Safety Thermostat

DHW Temperature

Sensor

Plate Heat Exchanger

14.11 Safety Thermostat (Fig. 85)

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. 85)

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

14.14 Pump - Head Only (Fig. 87)

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. 88).

4. Reassemble in reverse order.

14.15 Pump - Complete (Fig. 88)

1. Drain the boiler primary circuit.

Socket Headed

Screw

Pump Setting

Fig. 88

Pump Wiring

Cover

Pump Head

Automatic Air

Vent

Pump Body

Fig. 87

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.

14.16 Automatic Air Vent (Fig. 89)

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 Wiring

Cover

Fig. 89

14.0 Changing Components

Gauge Retaining

Fig. 90

Fig. 91

Hall Effect

Sensor

Bracket

Pressure Gauge

Capillary

14.17 Pressure Gauge (Figs. 90 & 91)

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.

14.18 Hall Effect Sensor (Fig. 92)

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.

14.19 Safety Pressure Relief Valve (Fig. 93)

Hydraulic Inlet

Assembly

Fig. 92

‘O’ ring seal

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.

Fig. 93

Discharge Pipe

Grub Screw

Pressure Relief Valve

14.0 Changing Components

14.20 Plate Heat Exchanger (Fig. 94)

Plate Heat Exchanger

LH Location Stud

Fig. 94

Rubber Seal

1. Drain the boiler primary circuit and remove the gas valve as described in section 14.24.

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.

14.21 Diverter Valve - Motor Unit & Assembly

(Fig. 95)

Motor Unit

Multi-pin Plug

Valve

Assembly

Pressure Sensor

Fig. 95

Retaining Clip

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

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

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

4. Drain the primary circuit and draw off any hot water once the isolating taps are closed.

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

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

Fig. 97

Control Box Cover

14.0 Changing Components

14.22 P.C.B. (Fig. 98)

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. 97).

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.

Selector

Switch

Facia

Selector Switch Knob

Fig. 98

P.C.B.

Drive Pins

Temperature Control Knobs

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

14.23 Selector Switch (Fig. 98)

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. 97).

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.

Venturi Inlet

Pipe

14.0 Changing Components

14.24 Gas Valve (Fig. 99)

Sensing Pipe

Power Lead

Earth Lead

Fig. 99

Gas Feed

Elbow

Gas Valve

Throttle

Adjustment Screw

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

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

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

3. Pull off the earth lead and sensing pipe.

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

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

Retaining Bracket

Expansion Vessel

Fig. 100

NOTE: To assist the boiler to light prior to final setting,

use a suitable hexagon key to wind out the throttle adjustment screw until it is flush with the valve body, then turn the screw 4 full turns clockwise (Fig. 100). If the boiler

will not light, or the correct CO

cannot be achieved

contact the ‘heateam’ technical helpline.

14.25 Expansion Vessel (Fig. 101)

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

2. Remove the screw retaining the air inlet pipe, and swing the pipe to one side.

3. Undo and remove the locknut securing the vessel spigot to the boiler lower panel.

4. Remove the bracket and vessel from the boiler.

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

6. Examine the sealing washer, replacing if necessary, and reassemble in reverse order.

Boiler Chassis

Fig. 101

Lock Nut

x 2

15.0 Setting the Gas Valve

Central Heating

Temperature Control

Selector Switch

Reset

Temperature Control

Display

Central Heating

Fig. 103

Fig. 102

Domestic Hot Water Temperature Control

bar

Domestic Hot Water

Temperature Control

Fig. 104

15.1 Setting the Gas Valve (CO

IMPORTANT: The CO

must be only be checked and

check)

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

1. The combustion (CO

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

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

3. Turn both control knobs fully anticlockwise, then quickly

turn the right hand knob

/4clockwise twice and back fully

anticlockwise (Fig. 102).

4. The display will now alternate between ‘SF’ and the current boiler temperature and both green LEDs will flash (Figs. 103 & 104).

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

6. The display will show ‘00’, indicating maximum rate, then revert to ‘P ‘ alternating with the current boiler temperature (Figs. 105, 106 & 107).

Fig. 105

Flue Adaptor Test

Plug

Point

Analyser Probe

Offset

Adjustment Screw

(cap fitted)

Reduce CO at min. rate

Increase CO at min. rate

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

Fig. 106 Fig. 107

Fig. 108

Throttle

Adjustment Screw

(cover removed)

Reduce CO

at max. rate

Gas Valve

Fig. 109

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

Increase CO at max. rate

7. Remove the plug from the flue sampling test point. Insert the analyser probe and allow sufficient time for the reading to settle (Fig. 108).

The CO

8. It is possible to alter the CO

should be 8.7% ± 0.2

by adjustment of the gas valve. Remove the plastic cover from the Throttle Adjustment Screw. At maximum rate the Throttle Adjustment Screw should be turned, using a suitable hexagon key, until the correct reading is obtained (Fig. 109).

Turning clockwise will reduce the CO

increase th e CO

9. The CO

must then be checked at minimum rate. Turn

. Anticlockwise will

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

The CO

should be 8.4% ± 0.2

10. With the boiler on minimum, the Offset Adjustment Screw must be altered, using a suitable hexagon key, after

removing the cap (Fig. 109). Turning anti-clockwise will

reduce the CO

. Clockwise will increase th e CO2.

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

12. Check the Combustion Performance (CO/CO

This must be less than 0.004.

ratio).

16.0 Electrical

16.1 Illustrated Wiring Diagram

Water Pressure Switch

X400

Central Heating NTC Sensor

9876

54321

Overheat Stat

910 8 7 6

54321

DHW NTC Sensor

Hall Effect

Sensor

X401

Flue Sensor

g/y

Fan

Optional Timer

1234

X501

Control PCB

X2 X3

1212 3344

556789

Link

Mains Input Cable

Flame Sensing Electrode

g/y

Spark Generator

Pump

Diverter Valve

Gas Valve

Ignition Electrode

br bk b w

- brown

- black

- blue

- white

- green

- green / yellow

g/y

- red

17.0 Short Par ts List

Short Parts List

315

422

306

316

404

311

419

426

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

311 Fan 5121447

426 Motor 3way Valve 5132452

315 Igniter Electrode 720222801

316 Sensing Electrode 5114703

422 Gas Valve 720301001

404 Hall Effect Sensor 5114767

306 Burner 24/28 5122149

Burner 33 5114697

302 Flue Sensor 720851401

419 Water Pressure Switch 5114748

400 Plate Heat Exchanger 24 248048

Plate Heat Exchanger 28/33 5114708

302

400

421

420

415

415 Pump 248042

421 NTC Sensor 5114725

420 Overheat Thermostat 5114729

504 Pressure Gauge 248090

503 PCB 24 5121862

PCB 28 720043401 PCB 33 720795201

503

504

18.0 Fault Finding

18.1 Initial Fault Finding Checks

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.

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

Table Of Error Codes

E20 E28 E50 E110 E119 E125 E130 E133 E160 E193

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

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.

Refer to Section 16.0 “Illustrated Wiring Diagram” for position of terminals and components

Central Heating - Follow operational sequence

18.0 Fault Finding

Turn selector switch to

The display illuminates

YES

Error 110 flashing Error 130 flashing Error 133 flashing

Error 20, 28 or 50 flashing

Error 119 flashing

Turn Central Heating

thermostat to Maximum.

Pump runs

YES

Error 125 or 193 flashing

YES YES

YES

Go to section ‘A’

Turn the selector switch to

reset position for 5 seconds

Go to section ‘E’

Go to section ‘C’

Ensure all controls (and

integral clock if fitted) are

calling for heat

Ensure that primary

circulation is OK & that

there is no blockage

YES

If the error 110 is still flashing.

Go to section ‘J’

Ensure controls are set to

demand and verify the

contacts are closed

Go to section ‘B’

3-way valve is open to Central

Heating circuit

YES

Fan runs

YES

Fan runs at correct speed

YES

Spark at ignition electrodes for

up to 5 seconds and for 3

attempts

YES

Burner lights

YES

YES YES

Go to section ‘K’

Error 160 flashing

Go to section ‘D’

Error 160 flashing

Go to section ‘L’

Error 133 flashing

Go to section ‘F’

Burner does not stay alights

after 5 seconds

Check the Central Heating

NTC sensor

Go to section ‘E’

YES

Go to section ‘H’

Turn the selector switch to

reset

Error 133 flashing

Go to section ‘I’

Burner output modulates to

maintain the temperature set

YES

Burner goes out

YES

Error 130 flashing Go to section ‘M’

Fan stops after 10 seconds

YES

Pump continues to run for 3

minutes

(room thermostat open)

YES

Operation sequence

successful

Domestic Hot Water - Follow operational sequence

18.0 Fault Finding

Turn selector switch to

The display illuminates

YES

Error 110 flashing Error 133 flashing

Error 20, 28 or 50 flashing

Error 119 flashing

Turn Domestic Hot Water

thermostat to Maximum.

Open DHW tap fully.

DHW Hall Effect sensor

operated (red neon on the

sensor illuminated

YES

3-way valve is open to

Domestic Hot Water circuit

YES

Go to section ‘A’

Turn the selector switch to

reset position for 5 seconds

Go to section ‘E’

Go to section ‘C’

DHW flow rate more than 2

l/min

Go to section ‘K’

YES

If the error 110 is still flashing.

Go to section ‘J’

Go to section ‘B’

YES

Is mains water filter and

assembly clean?

Is the magnetic detector free

to move in the Hall Effect

sensor

YES

Pump runs

YES

Fan runs

YES

Fan runs at correct speed

YES

Spark at ignition electrodes for

up to 5 seconds and for 3

attempts

YES

Burner lights

YES

Burner output modulates to

maintain the temperature set

YES YES

Error 125 flashing

Go to section ‘B’

Error 160 flashing Go to section ‘D’

Error 160 flashing

Go to section ‘L’

Error 133 flashing

Go to section ‘F’

Burner does not stay alights

after 5 seconds

Reduce DHW flow rate

Burner modulates

YES

Go to section ‘H’

Turn the selector switch to the

reset position for 5 seconds

Error 133 flashing

Go to section ‘I’

Clean DHW NTC sensor

and DHW heat exchanger

YES

Close DHW tap

YES

DHW flow sensor senses no

flow. Burner goes out

YES

Error 130 flashing

Go to section ‘M’

Fan stops after 10 seconds

YES

Pump runs for 30 seconds

YES

Operation sequence

successful

Fault Finding Solutions Sections

18.0 Fault Finding

Is there 230V at:

Main terminals L and N Check electrical supply

Main terminal fuse Replace fuse

3. PCB - X1 connector

terminals 1,2

Is there 230V at:

Pump Replace pump

PCB - X3 connector terminals 3 & 4 Replace PCB

Change pump supply cable

CH system pressure less than 0.5 bar Re-pressurise system

YES

If pump jammed, release

YES

Check wiring

YES

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

YES

Display illuminated

Replace water pressure switch

Replace PCB

Check the tap of the automatic air vent is opened

Fan connections correct at fan. PCB X2 connector, is 230V AC across terminals 5 & 7

YES

Open the automatic air vent

Fan jammed or faulty winding

Replace PCB

YES

Replace fan

18.0 Fault Finding

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

E28 - Incorrect PCB fitted

1. Check and correct the connection of the

tube between the venturi and gas valve

Gas at burner

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

Ensure gas is on and purged

PCB - X3 connector is 230V AC across

terminals 1 & 2

Replace PCB

Replace sensor or PCB (E28)

YES

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

Replace gas valve

YES

Check and correct if necessary

1. Ignition electrode and lead

2. Electrode connection

3. Spark gap and position

Sensing Electrode

7.5

Replace PCB

Voltage at PCB - X2 connector is at least 100V DC across terminals 2 & 5

YES

(Note: from multimeter connect ‘common’ to 2 & ‘volts’ to 5). Check wiring

YES

Spark Ignition Electrode

Replace Hall Effect Sensor

Replace PCB

Replace igniter

0.5 ±

18.0 Fault Finding

Check supply pressure at the

gas valve:-

Minimum 17mbar

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  A

Overheat thermostat operated or

faulty, i.e. continuity across

thermostat terminals

YES

Replace PCB

YES

Allow to cool. Continuity

across thermostat terminals

more than 1.5 ohm

Replace PCB

Replace flame sensing electrode

YES

Replace safety thermostat

Is there 230V at:

Motor 3-way valve Replace motor 3-way valve

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

YES

Change pump supply cable

1. Fan connections correct at fan.

PCB - X401 connector terminals 5,6,7 & 8

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

YES

Replace PCB

Replace fan

Replace sensor

If pump is running the heat exchanger could be obstructed

YES

Replace heat exchanger

19.0 Notes

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

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

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

Customer Name

Address

Boiler Make and Model

Boiler Serial Number

Commissioned by (print name)

Company Name

Company Address

To be completed by the customer on receipt of a Buildings Regulations Compliance Certificate*:

Building Regulations Notification Number (if applicable)

Time and Temperature Control to Heating Room Thermostat and

Programmer/Timer

Programmable

Room Thermostat

Load/Weather Compensation

Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer/Timer

Fitted

Yes

ppm Ratio

Yes

www.centralheating.co.uk

Yes

Temperature

Quantity

m /hr

mbar Gas Inlet Pressure

Gas Inlet Pressure (at maximum rate)

OR%ORCO

litres

Provided

Not Required

Combination Boiler

Optimum Start

Control

Heating Zone Valves

Hot Water Zone Valves

Thermostatic Radiator Valves

Automatic Bypass to System

Boiler Interlock

Telephone Number

Gas Safe Register Number

Telephone Number

Commissioning Date

The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer’s instructions

What inhibitor was used?

What system cleaner was used?

Gas Rate

Burner Operating Pressure (if applicable)

Central Heating Flow Temperature

Central Heating Return Temperature

Gas Rate

Burner Operating Pressure (at maximum rate)

Cold Water Inlet Temperature

Hot Water has been checked at all outlets

If required by the manufacturer, record the following

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

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

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

(To confirm satisfactory demonstration and receipt of manufacturer’s literature)

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

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

A Building Regulations Compliance Certificate will then be issued to the customer.

Heating and Hotwater Industry Council (HHIC)

Commissioning Engineer’s Signature

Customer’s Signature

Water Flow Rate

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

If yes and if required by the manufacturer, has a water scale reducer been fitted?

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5545/BS6798

If the condensate pipe terminates externally, has the pipe diameter been increased and weatherproof insulation fitted?

What type of scale reducer has been fitted?

CONTROLS Tick the appropriate boxes

ALL SYSTEMS

CENTRAL HEATING MODE

Measure and Record:

COMBINATION BOILERS ONLY

CONDENSING BOILERS ONLY

ALL INSTALLATIONS

DOMESTIC HOT WATER MODE Measure and Record

mbar

ft /hr

°C

m /hr

mbar

ft /hr

l/min

°C

CO/CO

Service Record

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

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

Service Provider

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

Always use the manufacturer’s speciﬁed spare part when replacing controls.

Service 1 Service 2

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Service 3 Service 4

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Service 5 Service 6

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Operative ID No.

Comments:

Signature:

Service 7 Service 8

Service 9 Service 10

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

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.

POTTERTON

A Trading Division of Baxi Heating UK Ltd (3879156)

Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 0844 871 1560 Technical Enquiries 0844 871 1555 Website www.potterton.co.uk e&oe

Comp No7200372-07 (7/12)

Baxi Potterton Heatmax Combi HE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual