main 12 HE, 15 HE, 18 HE, 24 HE, 9 HE User guide

Download

Installation & Service Instructions

Only a flue approved for the Main HE can be used.

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

Main HE

Condensing

Central Heating Boiler

Contents

1. Introduction.....................................................4

2. Technical Data.................................................6

3. Installation Requirements..............................8

3.1 General Information........................................8

3.2 Legislation, Standards & Codes of Practice....8

3.3 Gas Supply......................................................8

3.4 Electricity Supply.............................................9

3.5 Location of Boiler............................................9

3.6 Condensate Disposal....................................10

3.7 Air Supply......................................................11

3.8 Flue Systems...........................................11

3.9 Plume Displacement....................................18

3.10 Water Circulating Systems...........................22

4. Installation.....................................................26

4.1 Unpack, Prepare the Wall & Boiler................26

4.2 Install the Flue...............................................27

4.3 Electrical Connections..................................28

4.4 Connect the Gas Supply...............................29

4.5 Connect the Water System...........................29

4.6 Connect the Condensate Drain.....................29

5. Wiring Diagrams............................................30

6. Commissioning.............................................32

6.1 Commission the Systems.............................32

6.2 Commission the Boiler..................................32

6.3 Flush the System..........................................32

6.4 Final Adjustments.........................................33

6.5 Advise the User.............................................33

6.6 Documentation.............................................33

7. Control Sequence.........................................34

8. Fault Finding Guides.....................................35

9. Servicing & Parts Replacement...................42

9.1 Servicing Procedure.....................................42

9.2 General Access............................................44

9.3 PCB Enclosure.............................................44

9.4 Gas Valve......................................................44

9.5 Air Pressure Switch.......................................45

9.6 Spark Igniter..................................................45

9.7 Flow/Casting Sensors...................................45

9.8 Overheat Sensor...........................................45

9.9 Fan & Flue Hood...........................................46

9.10 Electrodes/Burner.........................................47

9.11 Injector..........................................................47

9.12 Combustion Chamber Insulation...................48

9.13 Condensate Trap...........................................49

9.14 Primary Heat Exchanger...............................50

9.15 Secondary Heat Exchanger..........................51

10. Short Spares List......................................52

Benchmark Commissioning Checklist ............54

Building Regulations and the Benchmark Commissioning Checklist

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

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

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

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

This company is a member of the Benchmark initiative and fully supports the aims of the programme. Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

Building Regulations require that installations should comply with manufacturer's instructions. It is therefore important that the commissioning checklist is completed by the installer. The relevant section of Building Regulations only relates to dwellings. Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure.

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

0086

ISO 9001

FM 00866

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Competent Person's

Self Certification Scheme

Install and Commission this appliance to manufacturer's

instructions

Complete the

Benchmark Checklist

If you notify via 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:

www.GasSafeRegister.co.uk

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

0800 408 5577

or log onto:

within 10 days

Complete the

Benchmark Checklist

LABC will record the data

and will issue a

certificate of compliance

1. Introduction

Potterton Main HE

Main 9 HE G.C. No. 41 474 01 Main 12 HE G.C. No. 41 474 02 Main 15 HE G.C. No. 41 474 03 Main 18 HE G.C. No. 41 474 04 Main 24 HE G.C. No. 41 474 05

Main HE boilers are fully automatically controlled, wall mounted, fan powered, balanced flue condensing boilers using a cast iron primary heat exchanger.

Main HE boilers meet the requirements of Statutory Instrument “The Boiler (Efficiency) Regulations 1993 No 3083” and deemed to meet the requirements of Directive 92/42/EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by: Notified Body 0087.

Product/Production certified by: Notified Body 0086.

For use with Natural Gas (G20) only at 20mbar and for use in GB/IE only.

Gas Safe

All Gas Safe registered engineers carry a 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

Identification

To gain access to the identification labels, pull the door down.

The data label is on a swing out plate located just above the operating lights and temperature control knob.

A seven digit version of the serial number is located on the operating label attached to the rear of the door.

Important Installation Notes

The boiler is suitable for use with fully pumped open vented and sealed systems with an indirect coil type high efficiency cylinder.

The gas type, supply size and pressure must be checked for suitability before connection.

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

For the boiler to operate correctly all air must be vented from the system prior to commissioning and the system itself must be suitably vented.

The system must be designed to always provide a route for water to circulate between the boiler flow and return.

For optimum boiler performance, pump performance must meet the requirements shown on Page 23.

Failure to flush and add inhibitor to the system may invalidate the boiler warranty.

Failure to commission the boiler correctly may result in the installer being charged for any visits made by Potterton.

be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner, except for permitted fair dealing under Copyrights, Designs and Patents Act 1988.

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

The Company Secretary, Baxi Heating UK Ltd, The Wyvern Business Park, Stanier Way, Derby, DE21 6BF.

Full acknowledgement of author and source must be given.

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

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.

Health and Safety Information for the Installer and Service Engineer

Under the Consumer Protection Act 1987 and Section 6 of the Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health.

Small quantities of adhesives and sealants used in the product are cured and present no known hazards. The following substances are also present.

Man-Made Mineral Fibre

a) Some component parts of this boiler (insulation

pads, gaskets and rope seals) are manufactured from man-made mineral fibre.

b) Prolonged or excessive exposure to this material

may result in some irritation to the eyes, skin or respiratory tract.

c) It is advisable to wear gloves when handling these

items.

d) Irritant dust will only be released from the items if

they are broken up or subjected to severe abrasion. In these instances a suitable dust mask and goggles should be worn.

e) Always thoroughly wash hands after installation,

servicing or changing components.

f) When disposing of any items manufactured from

man-made mineral fibre care must be exercised.

g) If any irritation of the eyes or severe irritation of

the skin is experienced seek medical attention.

Model Seasonal Efficiency

(SEDBUK) (%)

9 86.1 12 86.4 15 86.2 18 86.2 24 86.2

Models 9 HE 12 HE 15 HE 18 HE 24 HE

Heat Input - Gross kW 10.22 13.62 17.04 20.43 27.25

Btu/h 34,877 46,465 58,129 69,717 92,968

Heat Output

(Non Condensing) kW 8.82 11.78 14.76 17.72 23.63

Btu/h 30,093 40,181 50,350 60,466 80,641

Heat Output (Condensing) kW 9.50 12.64 15.66 18.83 24.94

Btu/h 32,430 43,111 53,431 64,232 85,105

Gas Rate m

/h 0.98 1.30 1.63 1.95 2.60

/h 34.5 45.9 57.5 68.9 91.9

Burner Pressure - Hot mbar 8.6 10.4 9.0 8.4 12.8

in wg 3.44 4.16 3.6 3.36 5.12

Gas Supply Pressure mbar 20 20 20 20 20

Injector Size mm 2.8 3.1 3.5 3.9 4.1

Water Content litres 2.3 - 9, 12 & 15 2.7 - 18 & 24

Boiler Weight kg 39.0 - 9, 12 & 15 42.8 - 18 & 24

(Lift/Installed - Dry)

Nox Class 2 2 2 2 2

Maximum Working Head 30.5m (100 ft)

Minimum Working Head 150mm (6 in)

Flow Temperature Range 63°C - 82°C

Gas Supply Connection 15 mm Tail

Flow/Return Connections 22 mm Copper

Condensate System Connection 21.5 mm PP

Electricity Supply 230v ~ 50Hz

External Fuse 3A

Internal Fuse Type 3.15AT

Power Consumption 80 Watts (excluding pump)

Electrical Protection IP20

Boiler Type C

12, C32, C52

Boiler Category CAT 1

H 2H - G20 - 20 mbar

2. Technical Data

SEDBUK Declaration for Main HE

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 have been certified by 0087.

595 mm

400 mm

5 mm

clearance

125 mm clearance

130 mm servicing clearance 50 mm installation clearance*

5 mm clearance

410 mm overall

clearance

850 mm

770 mm*

overall

clearance

Fan and Flue Hood

Air Pressure Switch

Secondary Heat Exchanger

Condensate Trap 75 mm

Gas Valve

Primary Heat Exchanger

PCB Enclosure

Burner & Electrodes

Flow Connection

Return Connection

Spark Igniter

Flow Sensor

Overheat Sensor

Casting Sensor

610 mm

servicing

clearance

260 mm

15 mm

clearance

Condensate Connection

Wiring Centre

Data Label

'O' Ring and Clip Joints

Gas Connection

Fig. 1

3.3 Gas Supply

The meter and supply pipes must be capable of delivering the required quantity of gas in addition to the demand from any other appliances in the house and must be governed at the meter.

The pipe diameter required will depend on the boiler model and the pipe length from the gas meter.

The gas installation should be in accordance with BS6891.

3. Installation Requirements

3.1 General Information

Optional Extras

Various flue extensions, bends, vertical flue kits, control accessories etc. are available as optional extras. These are detailed in a separate publication.

Lifting

Important - This product should be lifted and handled by

two people. Stooping should be avoided, and protective equipment worn when necessary. Carrying and lifting equipment should be used as required, for example when installing in a loft space.

3.2 Legislation, Standards & Codes of Practice

The boiler is suitable only for installation in GB and IE and must be installed in accordance with the

manufacturer’s instructions and the rules in force, and only used in a suitably ventilated location.

Any purpose provided ventilation should be checked periodically to ensure that it is free from obstruction.

Installation, Commissioning, Service & Repair

In GB, the installation must be carried out by a Competent Person. It must be carried out in accordance with the relevant requirements and current edition of:

The G

AS SAFETY (Installation and Use) REGULATIONS.

The appropriate BUILDING REGULATIONS either the Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland). The W

ATER FITTINGS REGULATIONS OR WATER BYELAWS in

Scotland. The I.E.E. WIRING REGULATIONS. Where no specific instructions are given, reference should be made to the relevant BRITISH STANDARD

CODES OF PRACTICE. Reference should also be made to B

RITISH GAS

GUIDANCE NOTES FOR THE INSTALLATION OF DOMESTIC GAS CONDENSING BOILERS.

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.

Important – Failure to install and commission this boiler to manufacturer’s instructions may invalidate the warranty. This does not affect your statutory rights. In IE, the installation must be carried out by a competent person and installed in accordance with the current edition of:

I.S.813 “D

OMESTIC GAS INSTALLATIONS”.

The current BUILDING REGULATIONS. Reference should also be made to the ETCI rules for electrical installation.

STANDARD B.S. 6891 B.S. 5440: Pt 1 B.S. 5440: Pt 2 B.S. 5546

B.S. 7074

B.S. 5449 B.S. 6798

B.S. 7593

B.S. 7671

SCOPE Gas Installation. Flues. Air Supply. Installation of hot water supplies

for domestic purposes.

Expansion vessels and ancillary equipment for sealed water systems.

Forced circulation hot water systems. Installation of gas fired hot water

boilers. Treatment of water in domestic hot water central heating systems. IEE Wiring Regulations

STANDARD I.S. 813

B.S. 5546

B.S. 7074

B.S. 5449 B.S. 7593

SCOPE Domestic Gas Installations.

Installation of hot water supplies for domestic purposes.

Expansion vessels and ancillary equipment for sealed water systems.

Forced circulation hot water systems. Treatment of water in domestic hot

water central heating systems.

In IE:

The following BS standards give valuable additional information

In GB the following Codes of Practice apply:

3.4 Electricity Supply

230V ~ 50Hz via a fused double pole switch with a contact separation of at least 3 mm in both poles.

There must be only one common isolator for the boiler and its control system, it must provide complete electrical isolation and be fitted adjacent to the boiler.

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

The power cable to the boiler must be 4-core to supply permanent live, neutral, earth and switched live.

Electrical installation should be in accordance with BS7671.

WARNING: THIS BOILER MUST BE EARTHED AND

CORRECTLY POLARISED.

3.5 Location of Boiler

The boiler must be mounted on a flat wall which is sufficiently robust to take the weight of the boiler.

Location

The boiler should be fitted within the building unless otherwise protected by a suitable enclosure.

Clearances

The boiler requires only the clearances shown on Page 7, after installation.

Combustible Wall

The boiler is suitable for installation to a combustible wall e.g. wood cladding, provided that the flue duct is not closer than 25 mm to combustible material. A metal sleeve should be installed to surround the flue duct to provide a 25 mm annular space. Further guidance is given in BS5440: Pt 1.

Timber Frame

If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institution of Gas Engineers Publication IGE/UP/7/ (Gas Installation in Timber Framed Housing).

Bath or Shower Room

If the boiler is fitted in a room containing a bath or shower, it cannot be fitted in zone 0, 1 or 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.

Cupboard or Compartment

A cupboard or compartment used to enclose the boiler must be designed and constructed specifically for this purpose. An existing cupboard or compartment may be used provided that it is modified for the purpose. Details of essential features of cupboard/compartment design including airing cupboard installations are given in BS6798 and BS5546.

Service Access

Pipes and wiring must not restrict service access to the boiler

Zone 1

Zone 0

Zone 2

Window Recess

0.6 m

Ceiling

Outside Zones

Zone 2

Zone 1

Zone 0

2.25 m

Window Recess Zone 2

0.6 m

Fig. A

Fig. B

In GB Only

Zone 2

3.6 Condensate Disposal

This boiler incorporates a 75 mm trap.

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

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

The pipe must always slope continually downward away from the boiler by at least 50 mm in every metre (approx. 2.5°). No air breaks are required in the pipe.

1. The pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP. Metal pipework is NOT suitable for use in condensate disposal systems.

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

3. To reduce the risk of condensate being trapped, as few bends and fittings as possible should be used.

4. When disposing 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 could affect the operation of the boiler.

5. Any condensate pipework external to the building (or in an unheated part of it e.g. garage) should not exceed 3 metres in length and when in an exposed position, waterproof insulation is recommended. It is also recommended that the pipe diameter is increased to 32 mm.

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

Examples are shown of the following methods of termination in order of preference:-

i) via an internal discharge branch

(e.g. sink waste) - Fig. 4. ii) to an internal soil & vent pipe - Fig. 5. iii) to a drain or gully - Fig. 6. iv) to a purpose made soakaway - Fig. 7.

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

Boiler

50 mm per metre (2.5°)

Minimum fall

Termination to an internal soil and vent pipe

450mm min

Boiler

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

Sink

Pipe must terminate above water level but below surrounding surface

Boiler

Pipe must terminate above water level but below surrounding surface

Termination to a drain or gully

Boiler

500mm min

Termination to a purpose made soak-away

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

Fig. 4

Fig. 5

Fig. 6

Fig. 7

3.7 Air Supply

The room in which the boiler is installed does not require a purpose provided air vent.

3.7.1 Ventilated Cupboard/Compartment

If the boiler is installed in a cupboard or compartment (with the exception of those installations covered by Section 3.7.2), permanent air vents are required in the cupboard or compartment, one at high level and one at low level, either direct to the outside air or to a room. Both high level and low level air vents must communicate with the same room or must be on the same wall to outside air. Both the high level and low level vent to a room must each have a free area as stated below. The free area of each vent may be halved if the ventilation is provided directly from outside.

Models: 9 HE: 92 cm

18 HE: 184 cm

12 HE: 123 cm

24 HE: 246 cm

15 HE: 154 cm

The minimum size of ventilated compartment is 850 mm high by 410 mm wide. If the cupboard or compartment has a door the depth must be a minimum of 275 mm. This will allow for a minimum of 15 mm clearance between the front of the boiler and the door for air movement.

3.7.2 Unventilated Compartment

The 9, 12 and 15 models can be installed in an unventilated compartment providing the following conditions are met and no other heat sources are present within the compartment:

1. Minimum sizes for alternative compartments that include the required clearances are shown in Table 1.

2. Maximum Horizontal flue length from turret for boiler in unventilated compartment is 560 mm.

Ventilation should be in accordance with BS 5440: Pt 2.

3.8 Flue Systems

Horizontal

The standard flue/terminal assembly can be cut and is suitable for an installed length from 160 mm up to 700 mm.

1 m flue extensions are available. Maximum straight flue length 3.55 m (3 extensions) (equivalent resistance = 3.55 m). It is recommended that the flue is supported at least once per metre.

All lengths quoted exclude the boiler elbow.

Example layouts are shown on the Page 13.

Bends

A 93° bend is equivalent to a 1m length of flue. A 135° bend is equivalent to a 0.5m length of flue.

Vertical

For information on vertical flues consult the instructions supplied with the vertical flue kits.

3.8.1 Flue Terminal Location

The following guidelines indicate the general requirements for siting balanced flue terminals.

• With a condensing boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue and the effect it could have on neighbouring property and occupants.

• If a terminal is less than 2 metres above a balcony, above ground, or above a flat roof to which people have access a suitable terminal guard must be fitted centrally about the terminal.

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

• For fitting under low soffits, eaves and to extend beyond guttering it is acceptable for the flue to project up to 500 mm from the face of the wall to the inside of the air intake. This can be painted if required using a suitable external paint.

The terminal location should be in accordance with, in GB, BS 5440 Pt. 1. and IE, I.S. 813 "Domestic Gas Installations".

Table 1

Unventilated Compartments

Example 1 Example 2

Height 1295 mm Height 990 mm Width 550 mm Width 750 mm Depth 540 mm Depth 750 mm

Minimum clearances within compartment

Top 450 mm Top 265 mm Bottom 250 mm Bottom 130 mm Side 75 mm Side 175 mm Front 280 mm Front 490 mm

IMPORTANT:

• Only ONE 25mm clearance is allowed per installation.

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

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

Fig. 8

Fig. 9

300 min

Terminal Assembly

Top View Rear Flue

Property Boundar y Line

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

Terminal Position with Minimum Distance (Fig. 8) (mm)

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

From a terminal facing a terminal (Vertical flue). 600

L From an opening in carport (e.g. door, window)

into the dwelling. 1200

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

In addition, the terminal should be no nearer than 150 mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame. See BS 5440 Pt. 1.

Opening Window or Door

100mm MIN.

IMPORTANT: If fitting a Plume Displacement Flue Kit, the air inlet must be a minimum of 100mm from any opening windows or doors (see Plume Displacement Section 3.9).

Plume Displacement Kit

Air Inlet

Fig. 10

J,K

Likely flue positions requiring a flue terminal guard

J,K

3.8.2 Horizontal Flue Systems

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

2. Maximum permissible equivalent flue lengths is:-

Horizontal Concentric 3.55m

3. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes:

135° bend 0.5 metres 93° bend 1.0 metres

Twin Flue Pipe

135° bend 0.25 metres

91.5° bend 0.50 metres

The elbow supplied with the standard horizontal flue 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.

Horizontal Flues

Plume Displacement Kit

60 /100 Ø

1M Extensions, 45° & 93°

elbows are also available - see

Plume Displacement

Section 3.9

NOTE: Horizontal flue pipes should always be installed with at least a

1.5° fall from the terminal to allow condensate to run back to the boiler.

This bend is equivalent to 1 metre

Total equivalent length =

A+B+C+2x90°Bends

This bend is equivalent to 1 metre

Vertical Flues (Twin Pipe)

Vertical Flues

The total equivalent length for this

example is = 5.5 metres.

1m extension

135°bend

91.5°bend

0.25m

0.5m

4.0m

0.5m

1.0m

AIR DUCT

Noof

fittings/pipes

Sub total

Equivalent

Length Value

Equivalent Length Air Duct = 5.5m

1m extension

135°bend

91.5°bend

0.25m

0.5m

4.0m

0.5m

1.0m

FLUE DUCT

Noof

fittings/pipes

Sub total

Equivalent

Length Value

Equivalent Length Flue Duct = 5.5m

Roof

Terminal

This bend is equivalent to 1 metre

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

All vertical and angled runs must be included, measured from the boiler adaptor (point X) to the joint with the flue terminal (point Y). One

91.5° bend or two 135° bends can be included without reduction of the flue length.

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

1 metre for each 91.5° bend

0.5 metre for each 135° bend

3.8.3 Twin & Vertical Flue Systems

1. Maximum permissible equivalent flue lengths are:-

Vertical Concentric 1.9m Vertical Twin Pipe 6m*

* Both the air and flue duct can be up to 6 metres long each.

2. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes:

135° bend 0.5 metres 93° bend 1.0 metres

Twin Flue Pipe

135° bend 0.25 metres

91.5° bend 0.50 metres

The elbow supplied with the standard horizontal flue 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.

Key Accessory Size Baxi Code No

FLUE GROUP A Concentric Flue System 100mm diameter

A3 Telescopic Internal Flue Kit 315-500mm 5119654 A2 Telescopic Flue

(incl elbow) 5118069

A Horizontal flue Terminal

(incl elbow) 5118489

B Flue extension 1000mm 5111074 C Flue Bend 93° 5111075 D Flue Bend

(pair) 135° 5111085

U Pipe support

(painted) 100mm 5111080

R Vertical flue adaptor

(use with 5111078) 5111070

T Vertical flue boiler adaptor 5111065 P Wall Liner 5111067 S Flue Terminal Deflector 5111068

FLUE GROUP N Twin Flue System 80mm diameter

E Flue extension

(pair) 1000mm 5111087

F Flue Bend

(pair) 90° 5111072

G Flue Bend

(2 pair) 135° 5111086

O Vertical flue boiler adaptor kit 5111071 H Vertical flue adaptor 5111084 W Pipe support

(pair) 80mm 5111081

FLUE GROUP A, N,

Vertical Flue Kits

K Vertical flue terminal

(use with 5111070) 5111078

L Lead tile 25°/50° 5122151 M Roof cover plate 246143 N Flat roof flashing 246144

U,W

3.8.4 Flue Accessories

For Twin Flue Systems fit the adaptors as follows:-

3.8.5 Vertical Flue Duct Adaptor (Fig. 11)

1. Remove the flue elbow from top of the boiler and replace with the vertical flue duct adaptor ensuring the existing gasket is still in place.

3.8.6 Twin Vertical Flue Boiler Adaptor (Fig. 12)

1. Remove the flue elbow from top of the boiler and replace with the twin vertical flue duct adaptor ensuring the existing gasket is still in place.

2. Attach the rubber spacer to the base of the adaptor.

3. Fit the adaptor to the top of the boiler and secure it to the four hole fixing plate using the long screws supplied.

4. Continue to fit the twin flue system.

Vertical Flue Boiler Adaptor

Gasket

Position of Adaptor

Twin Vertical Flue Boiler Adaptor

Fig. 11

Fig. 12

Screw

Original seal

Four hole fixing plate

Stick rubber spacer here

Fig. 13

Fig. 14

100mm

685mm

Push Fit Adaptor

Air Duct

Flue Duct

Cut the same amount off the Air Duct & Flue Duct

Approx

1425mm

3.8.7 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.

3.8.8 Flue Dimensions

The standard horizontal flue kit allows for flue lengths between 100mm and 685mm from elbow to terminal (Fig. 13).

The maximum permissible equivalent flue length is: 3.55 metres

NOTE: Each additional 45° of flue bend will account for an equivalent flue length of 0.5m. eg. 45° = 0.5m, 90° = 2 x 45° = 1m etc.

3.8.9 Flue Trim

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

3.8.10 Terminal Guard (Fig. 14)

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

2. There must be a clearance of at least 50mm between any part of the terminal and the guard.

3. When ordering a terminal guard, quote the appliance name and model number.

4. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated.

3.8.11 Flue Deflector (Fig. 13a)

1. If required a flue deflector is available from your Main stockist.

2. 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.

Flue Deflector

Fig. 13a

+ 39 hidden pages

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Specifications and Main Features

Frequently Asked Questions

User Manual