Baxi Potterton Heatmax Combi HE User Manual

You can rely on

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With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn.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

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