main Eco Elite 25 Combi ErP User guide

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Main Eco Elite Combi

Installation & Service Manual

United Kingdom

Condensing Central Heating Boiler

25 - 30

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safw keeping.

Natural Gas

Main Eco Elite 25 Combi ErP

47 467 12

G.C.N

Main Eco Elite 30 Combi ErP

G.C.No47 467 13

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With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn.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 2015 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 Ltd, Brooks House, Coventry Road, Warwick. CV34 4LL

Full acknowledgement of author and source must be given.

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.

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

0086

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.

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.

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

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

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 0086.

Product/Production certified by: Notified Body 0086.

For GB/IE only.

Homologations

CE Marking

EC - Declaration of Conformity

Baxi Heating UK Limited being the manufacturer / distributor within the European Economic Area of the following

Main Eco Eliite 25 Combi ErP Main Eco Elite 30 Combi ErP

declare that the above is in conformity with the provisions of the Council Directive

2009/142/EC 92/42/EEC 2004/108/EC 2006/95/EC 2009/125/EC 2010/30/EU

and has been subject to the following conformity procedures laid down in

Annex 2 - Article 3 of 2009/142/EC

under the supervision of the British Standards Institution, a Notified Body authorized by the United Kingdom Competent Authority, and carrying the Notified Body Number 0086.

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

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

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

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

BS EN 12828 Heating systems in buildings. BS EN 14336 Installation & commissioning of water based

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

BS 7593 Treatment of water in domestic hot water

In IE the following Codes of Practice apply: Standard Scope

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

BS EN 12828 Heating systems in buildings. BS EN 14336 Installation & commissioning of water based

BS 7074 Expansion vessels and ancillary equipment for

BS 7593 Treatment of water in domestic hot water

purposes.

heating systems.

sealed water systems.

central heating systems.

purposes.

heating systems.

sealed water systems.

central heating systems.

Type test for purpose of Regulation 5 certified by: Notified Body 0086.

Product/Production certified by: Notified Body 0086.

For GB/IE only.

Safe Manual Handling

General

The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.

Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health & Safety is the responsibility of EVERYONE.

There is no ‘safe’ limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.

Do not handle or lift unless you feel physically able.

Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.

Preparation

Co-ordinate movements - know where, and when, you are both going.

Minimise the number of times needed to move the boiler - plan ahead.

Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special care on ladders/into lofts.

Technique

When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body as possible.

Where possible transport the boiler using a sack truck or other suitable trolley.

Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the ‘Installation’ section of these instructions for recommended lift points.

Remember

The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.

If at any time when installing the boiler you feel that you may have injured yourself STOP !! DO NOT ‘work through’ the pain - you may cause further injury.

IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!

CONTENTS

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 12

6.0 System Details 13

7.0 Site Requirements 16

8.0 Flue Options 21

9.0 Installation 23

10.0 Commissioning 28

11.0 Completion 31

12.0 Servicing 32

13.0 Changing Components 34

14.0 Setting the Gas Valve 43

15.0 Electrical 44

16.0 Short Parts List 45

17.0 Fault Finding 46

18.0 Notes 52

Benchmark Checklist 54

Case Front Panel

1.0 Introduction

1.1 Description

1. The Main Eco Elite Combi 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 :-

25 model - 25.94 kW DHW

26.95 kW CH Pnc (Condensing)

30 model - 28.63 kW DHW

30.2 kW CH Pnc (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 numbe. It is visible when the case front panel is removed (Fig. 1).

Control Box

Fig. 1

Facia Door

Data Badge

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 / domestic 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).

Information Label

1.2 Contents of Pack

1. Boiler Unit

2. Wall Plate (inc. taps)

3. Set of Pipes (inc. nuts)

4. Template

5. Literature Pack

7. Filling Loop

8. 24 hr. Electro - Mechanical Timer

2.0 General Layout

2.1 Layout

1. Expansion Vessel

2. Automatic Air Vent

3. DHW Plate Heat Exchanger

4. Circulation Pump

5. Drain Off Point

6. Pressure Relief Valve

7. Selector Switch

8. Central Heating System Pressure Gauge

9. PCB

10. Control Box

11. 3-Way Valve Assembly

12. Condensate Trap

13. Heat Exchanger Air Vent

14. Electrode Assembly

15. Primary Heat Exchanger

16. Fan Assembly

17. On/Off/Reset Selector Switch

18. Central Heating Temperature Control

19. Hot Water Temperature Control

20. Water Pressure Sensor

21. Gas/Air Inlet

22. Burner Mounting Panel

23. Igniter

24. Burner On Light

25. Central Heating Mode Light

26. Domestic Hot Water Mode Light

27. Display

28. Position for Integral Timer

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 5 Gas 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 27 Heat Exchanger Air Vent

3.1 Central Heating Mode (Fig. 2)

1. With a demand for heating, the pump circulates water through the primary circuit.

2. Once main burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor.

3. When the flow temperature exceeds the setting temperature, a 3 minute delay occurs before the burner relights automatically (anti-cycling). The pump continues to run during this period.

4. When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes (Pump Overrun).

3.2 Domestic Hot Water Mode (Fig. 3)

1. Priority is given to the domestic hot water supply. A demand at a tap or shower will override any central heating requirement.

2. The flow of water will operate the Hall Effect Sensor which requests the 3 way valve to change position. This will allow the pump to circulate the primary water through the DHW plate heat exchanger.

3. The burner will light automatically and the temperature of the domestic hot water is controlled by the temperature sensor.

4. When the domestic hot water demand ceases the burner will extinguish and the diverter valve will remain in the domestic hot water mode, unless there is a demand for central heating.

IMPORTANT: When the selector switch is in the ‘0’ (Off) position the electrical supply to the boiler is isolated. The boiler will not operate and the integral timer will require resetting once the selector switch is set to either Position ( ) or Position ( ).

3.3 Frost Protection Mode

Fig. 3

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 Main Eco Elite 25 & 30 Combi ErP

Appliance Type C

Appliance Category CAT I

Heat Input CH Qn Hs (Gross)

Max Min

25 model kW 28.92 8.68

30 model kW 32.54 9.77

Heat Output CH Pn (Non-Condensing)

Max Min

25 model kW 25.94 7.61

30 model kW 28.63 8.56

Heat Output CH Pnc (Condensing)

Max Min

25 model kW 26.95 8.37

30 model kW 30.2 9.42

Heat Input DHW Qnw Hs (Gross)

Max

25 model kW 28.92

30 model kW 33.30

Heat Output DHW Max

25 model kW 24.88

30 model kW 30.00

Max Gas Rate (Natural Gas - G20)

(After 10 mins)

25 model m3/h 2.76

30 model m3/h 3.17

Product Characteristic Database

(SEDBUK)

SAP 2009 Annual Efficiency

25 - 89.0 % 30 - 88.7 %

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 0086.

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)

6.0mm

Electrical Supply 230V~ 50H

(Appliance must be connected to an

earthed supply)

Power Consumption

25 & 30 105W

Electrical Protection

IPX0D (with timer) IPX4D (without timer)

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 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 175 mm Min

300mm Min (80/125) Below Casing 200 mm Min Front 450 mm Min (For Servicing) Front 5 mm Min (In Operation) L.H. Side 5 mm Min R.H. Side 5 mm Min (In Operation)

Weights 25 & 30

Packaged Boiler Carton 51.0 kg Installation Lift Weight 45.0 kg

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 (25) (30)

l/min l/min DHW Flow Rate @ 30o C Rise 11.9 14.3

DHW Flow Rate @ 35o C Rise 10.2 12.3

Min Working DHW Flow Rate 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.

Pump

Available Head See graph below

Expansion Vessel - (For Central Heating only. Integral with appliance)

bar

Min Pre-charge Pressure 0.5

Max Capacity of litre CH System 125

For greater system capacities an

additional expansion vessel MUST be fitted.

Primary Water Content of Boiler (unpressurised) 3.1

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

5.5

4.5

3.5

2.5

Metre (wg)

1.5

0.5

200 400 600 800 1000 1200 1400

Flow Rate (l/h)

4.0 Technical Data

See

4.2 Technical Parameters

Technical parameters for boiler combination heaters

Main Eco Elite Combi ErP

Condensing boiler

Low-temperature boiler

(1)

B1 boiler

Cogeneration space heater

Combination heater

Rated heat output

Useful heat output at rated heat output and high temperature regime

(2)

Useful heat output at 30% of rated heat output and low temperature regime

(1)

Seasonal space heating energy efficiency

Useful efficiency at rated heat output and high temperature regime

(2)

Useful efficiency at 30% of rated heat output and low temperature regime

(1)

Auxiliary electricity consumption

Full load

Part load

Standby mode

Other items

Standby heat loss

Ignition burner power consumption

Annual energy consumption

Sound power level, indoors

Emissions of nitrogen oxides NO

Prated

elmax

elmin

stby

ign

kWh GJ

mg/kWh

Yes Yes

No No

Yes Yes

26 29

25.9 28.6

8.4 9.5

92 92

89.7 88.0

97.0 97.0

0.049 0.098

0.016 0.016

0.003 0.003

0.061 0.061

22557 24896

81 90

50 50

25 30

Domestic hot water parameters

Declared load profile

Daily electricity consumption

Annual electricity consumption

Water heating energy efficiency

Daily fuel consumption

Annual fuel consumption

(1) Low temperature means for condensing boilers 30°C, for low temperature boilers 37°C and for other

heaters 50°C return temperature (at heater inlet).

(2) High temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature

at heater outlet.

elec

AEC

fuel

AFC

kWh

XL XL

0.200 0.191

44 42

81 88

24.251 21.845

18 17

S The back cover for contact details.

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

127 mm

Condensate

Drain

At Least 1.5

5.0 Dimensions and Fixings

Dimensions

A 780mm

360° Orientation

B 345mm

C 450mm

D 116mm Ø Min.

F 145mm

G 106mm

210mm (80/125)

H 225mm

Tube Ø 100mm

Tap Rail

6.0 System Details

6.1 Information

1. The Main Eco Elite Combi 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. Further external controls (e.g. room thermostat) should be fitted to optimise the economical operation of the boiler.

6.0 System Details

6.5 System Filling and Pressurising (Fig. 4)

Fig. 4

Stop Valve

DHW Mains Inlet

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.

2. A filling loop is supplied with the boiler in the installation kit. Follow the instructions provided with it to connect to the taps shown in Fig.5.

3. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment.

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

5. 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.

Filling Loop Connections

Fig. 5

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”.

6.7 Safety Pressure Relief Valve (Fig. 6)

1. The pressure relief valve is set at 3 bar, therefore all pipework, fittings, etc. should be suitable for pressures in excess of 3 bar and temperature in excess of 100°C.

2. The pressure relief discharge pipe should be not less than 15mm dia, run continuously downward, and discharge outside the building, preferably over a drain. It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components. The end of the pipe should terminate facing down and towards the wall.

Pressure Relief Valve

Fig. 6

Discharge Pipe

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.

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. Only water that has NOT been artificially softened must used when filling or re-pressurising the primary system. If the mains cold water to the property is fitted with an artificial softening/treatment device the source use to fill or re-pressurise the system must be upstream of such a device.

7.0 Site Requirements

Fig. 8

5mm Min

450mm

5mm Min

175mm Min

(300mm Min if

using 80/125mm

flueing system)

780mm

200mm 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°

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.

Fig. 9

5mm Min

In Operation

7.0 Site Requirement

Gas Service Cock

Fig. 10

Zone 1

Zone 0

Zone 2

Window Recess

Zone 2

7.3 Ventilation of Compartments

1. Where the appliance is installed in a cupboard or compartment, no air vents are required.

2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.

7.4 Gas Supply

1. The gas installation should be in accordance with the relevant standards. In GB this is BS 6891. In IE this is the current edition of I.S. 813 “Domestic Gas Installations”.

2. The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock (Fig. 10).

3. Ensure that the pipework from the meter to the appliance is of adequate size. Do not use pipes of a

smaller diameter than the boiler gas connection (22mm).

7.5 Electrical Supply

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

Fig. 11

Zone 1

Zone 0

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

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 FITTED with any integral timer or thermostat, it can be fitted in zone 2, (Figs. 11 & 12 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. 12

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.

Insulation

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

2.5° Minimum fall

Sink

21.5mm

i) Termination to an internal soil and vent pipe

50mm per metre of pipe run

450mm min*

Boiler

ii) External termination via internal discharge branch

50mm per metre of pipe run

2.5° Minimum fall

32mm

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

e.g sink waste - downstream*

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.

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.

/4in) plastic

Boiler

50mm per metre of pipe run

Boiler

iii) Termination to a drain or gully

2.5° Minimum fall

iv) Termination to a purpose made soakaway

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

50mm per metre of pipe run

2.5° Minimum fall

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

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

500mm min

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

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.

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.

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 Boundar y Line

Terminal Position with Minimum Distance (Fig. 14) (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) 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 MUST be as shown in brackets, in accordance with 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 (Figs. 13 & 14)

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

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

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

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

3. If a terminal is less than 2 metres above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be provided.

IMPORTANT:

• 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.

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

Fig. 13

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.

J,K

Air Inlet

Opening Window or Door

150mm MIN.

J,K

Likely flue positions requiring a flue terminal guard

Fig. 14

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 the lubricant supplied 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

Horizontal Flues

Plume Displacement Kit 60 /100 Ø

1M Extensions, 45° & 93° elbows

are also available - see Section 9.0

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

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 supplied with the standard horizontal

telescopic flue kit is not included in any equivalent length calculations.

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

IMPORTANT SUPPORT - All flue systems MUST be securely supported a MINIMUM of once every metre. It is recommended that every straight piece is supported irrespective of length. Additional supports are available as accessories. VOIDS - Consideration must be given to flue systems in voids and the provision of adequate access for subsequent periodic visual inspection.

6. Read this section in conjunction with the Flue Installation

Guide supplied with the boiler.

(ii)

This bend is equivalent to 1 metre

(i)

Total equivalent length =

A+B+C+2x90°Bends

Fig. 15

315mm 500mm

Flue Deflector

8.0 Flue Options

8.2 Flue Lengths

The standard horizontal telescopic flue kit allows for lengths between 315mm and 500mm from elbow to terminal without the need for cutting (Fig. 15). Extensions of 250mm, 500mm & 1m are available.

The maximum permissible equivalent flue length is:

10 metres (60/100 system - vertical & horizontal) 20 metres (80/125 system - vertical & horizontal) 15 metres (80/80 twin pipe)

8.3 Flue Trim

1. The flexible flue trims supplied can be fitted on the outer

and inner faces of the wall of installation.

8.4 Terminal Guard (Fig. 16)

1. When codes of practice dictate the use of terminal guards

‘Multifit’ accessory part no. 720627901 can be used (Note: This is not compatible with Flue Deflector referred to below).

Ensure that no part of the white outer

chimney duct is visible

Fig. 16

Flue Accessories & Fitting Guide Ø 60/100 Flue Systems Ø 80/125 Flue Systems Ø 80/80 Twin Flue Systems Plume Displacement Kit (Ø 60/100 Flue Systems)

READ THESE INSTRUCTIONS IN CONJUNCTION WITH THE BOILER

INSTALLATION INSTRUCTIONS BEFORE FITTING THE FLUE

GUIDANCE NOTES

IMPORTANT NOTE:This document will assist in the correct installation of the various flue & chimney systems described within. However, it is the responsibility of the installer/Gas Safe registered commissioning engineer to ensure that the flue & chimney system is fitted safely and in compliance with the relevant standards and practices in force in the country of installation.

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.

8.5 Flue Deflector

1. Push the flue deflector over the terminal end. It may point

upwards as shown, or up to 45° either way from vertical. Secure the deflector to the terminal with screws provided.

8.6 Flue Accessories (Fig. 16a)

1. For full details of Flue Accessories (elbows, extensions,

clamps etc.) refer to the Flue Installation Guide supplied in the literature pack.

Fig. 16a

Please leave these instructions with the Installation & Servicing Instructions.

Fig. 17

Pre-plumbing

SNAP OFF

LIFT HERE BOTH SIDES

1.0 Introduction

9.0 Installation

9.1 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. See section ‘Safe Manual Handling’ before unpacking or lifting the boiler.

RISK ASSESSMENT Before commencing the installation it is recommended that the ‘Five Steps to Risk Assessment’ document published by the HSE is consulted, and an assessment performed as described.

2. Follow the procedure on the carton to unpack the boiler or see Fig. 17.

3. If pre-plumbing (Fig. 18) - the wall jig and fitting kit can be removed without removing the carton sleeve. Simply slide banding to the edge and open the perforated flap, lift out the jig, fitting kit and instructions. If the boiler is to be installed at a later date, close the flap and reposition the banding straps, the boiler can now be stored safely away.

To remove only the wall jig slide

banding to the edge and open flaps.

Fig. 18

For Side Flue Exit

Fig. 19

Flushing Tube

Slide the wall jig out of carton then

close the flaps. Slide banding back on.

145mm

Wall Plate

4. After considering the site requirements (see Section 7.0) position the fixing template on the wall ensuring it is level both horizontally and vertically.

5. 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.

6. Mark the position of the centre of the flue hole (rear exit). For side flue exit, mark as shown (Fig. 19).

7. If required, mark the position of the gas and water pipes. Remove the template.

8. Cut the hole for the flue (minimum diameter 116mm).

9. Drill the wall as previously marked to accept the wall plugs supplied. Secure the wall plate using the fixing screws.

10. Using a spirit level ensure that the plate is level before finally tightening the screws.

11. 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.

12. Fit the filling loop as described in the instructions supplied with it.

Central Heating Return

9.2 Flushing

1. Connect a tube to the central heating flow or return pipe (Fig. 20).

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

Fig. 20

Remove Sealing Caps from under the Boiler after lifting into position

9.0 Installation

9.3 Fitting The Boiler (Fig. 21)

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 and the

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

Fig. 21

Sealing Washers

Lift Here Both Sides

Bottom Polystyrene

When the Boiler Mounting Bracket on the

Boiler is in position on the Retaining Lugs, the bottom polystyrene may be discarded

allowing the boiler to swing into position

3. Insert the sealing washers between the valves and pipes

on the wall plate and the boiler connections.

4. Tighten all the connections.

9.4 Fitting the Safety Pressure Relief Discharge Pipe

(Fig. 22)

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.

Safety Pressure Relief Valve

Fig. 22

Discharge Pipe

9.5 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.

500mm

9.0 Installation

Wall Thickness

(X)

Fig. 23

315mm

Connection Assembly

(X)

Terminal Assembly

Fig. 22

Wall

Thickness

9.6 Fitting The Flue

HORIZONTAL TELESCOPIC FLUE

1. There are two telescopic sections, the Terminal Assembly and the Connection Assembly, a roll of sealing tape and two self tapping screws. A 93° elbow is also supplied.

2. The two sections can be adjusted to provide a length between 315mm and 500mm (Fig. 22) when measured from the flue elbow (there is 50mm engagement into the elbow).

3. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (Fig. 23).

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

4. Measure the distance from the outside wall face to the elbow. This dimension will be known as ‘X’ (Fig. 23).

5. If the distance from the flue elbow to the outside face of the wall (‘X’ in Fig. 23) is less than 250mm the Connection Assembly can be discarded and the Terminal Assembly fitted directly into the elbow.

6. In instances where the dimension ‘X’ (Fig. 23) is between 250mm and 315mm it will be necessary to shorten the Terminal Assembly by careful cutting to accommodate walls of these thicknesses.

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

Dimension ‘Y’

Fig. 24

‘TOP’ Label

Sealing Tape

Fig. 25

‘Peak’ to be uppermost

8. Adjust the two telescopic sections to dimension ‘Y’ and seal the joint with the tape provided (Fig. 25). Ensure that the labels marked ‘TOP’ on the Terminal and Connection Assemblies are uppermost.

9. Using the clearance holes in the Connection Assembly secure it to the Terminal Assembly using the screws supplied (Fig. 26).

Securing Screw

Fig. 26

Apply the lubricant supplied for ease of assembly (do not use any other type).

Ensure Flue is fully engaged into Elbow

Flue Elbow

Adaptor

Fig. 27

9.0 Installation

9.6 Fitting the Flue (Cont)

10. Remove the flue elbow and insert the flue through the hole in the wall.

11. Refit the elbow to the boiler adaptor, ensuring that it is pushed fully in (Fig. 27).

12. Two flue trims are supplied, one for internal use, the other for outside. The internal trim is packaged and identified as such - it should not be used externally.

13. It is recommended that if the internal trim is being used it is first fitted over the elbow to allow access to the securing screws and then manouvered into place against the wall.

14. Draw the flue back through the wall and engage it in the elbow. It may be necessary to lubricate to ease assembly of the elbow and flue (Fig. 28).

Flue to elbow

securing screws

Elbow to adaptor

securing screws

Trims

Fig. 28

15. Ensure that the terminal is positioned with the slots to the bottom (Fig. 29). Secure the flue to the elbow with the screws supplied (Fig. 28).

16. Secure the elbow flue to the boiler adaptor with the screws supplied in the boiler fittings pack (Fig. 28).

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

17. Make good between the wall and air duct outside the building, appropriate to the wall construction and fire rating.

18. If necessary fit a terminal guard (see Section 8.4).

Slots at bottom

Fig. 29

Fig. 32

Cable Clamp

Terminal Block Cover

9.0 Installation

9.7 Making The Electrical Connections

NOTE: Both the Live and Neutral connections are fused.

Integral Timer: If required the integral timer supplied in

the boiler installation kit should be fitted at this stage. Fitting instructions are included with it.

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. 31).

3. Undo the terminal block cover securing screw and remove the cover (Fig. 31).

Fig. 33

Fused Spur

Fig. 31

Facia Panel

4. Slacken the unused cable clamp on the LH side of the boiler chassis (Fig. 32). Insert the external control wiring through the clamp and route it to the terminal block.

5. Refer to the instructions supplied with the control.

IMPORTANT: The room thermostat MUST be suitable for 230V switching.

Room ‘Stat

NOTE: An external frost thermostat cannot be used in conjunction with the integral timer supplied in the boiler installation kit.

6. Remove the link between terminals 1 & 2. The 230V supply at terminal 2 must be connected to the thermostat.

230V

g/y

The switched output from the thermostat must be connected to terminal 2. (Fig. 33). If the room thermostat

being used incorporates an anticipator it MUST be wired as shown in Fig. 33.

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.

Frost Thermostat

Room ‘Stat

230V

8. Replace the terminal block cover, routing the external control input cable(s) through the second cut-out.

9.8 Preliminary Electrical Checks

External Clock

230V

g/y

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

2. These should be performed using a suitable meter, and include checks for Earth Continuity,

Resistance to Earth, Short Circuit and Polarity.

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.

bar

Heat Exchanger

Automatic Air Vent

Screw

10.0 Commissioning

Fig. 34

10.1 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.

IMPORTANT: The heat exchanger air vent on top of the boiler (Fig. 34) MUST be opened before filling the primary system.

Fig. 35

Selector Switch

Reset

Fig. 37

Automatic Air

Pump

Display

Central Heating

Temperature Control

Pump

Vent

Fig. 36

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. 34).

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. 36) 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 soundness.

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

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:

11. The Combustion Check procedure as shown by the chart

in 10.2 is mandatory. The method of setting the boiler to operate at maximum and minimum rates to comply with the procedure is described below.

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

13. Turn both control knobs fully anticlockwise, then quickly turn the right hand knob 1/4 clockwise twice and back fully anticlockwise (Fig. 37).

14. The display will now alternate between ‘SF’ and the current boiler temperature and both green LEDs will flash.

15. To set to maximum rate. Turn the left hand knob fully clockwise. As the knob is turned the display will change, indicating the fan speed.

16. The display will show ‘00’, indicating maximum rate, then revert to ‘P ‘ alternating with the current boiler temperature.

17. To set to minimum rate. Turn 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.

18. This 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.

Verify Flue Integrity

Indication that products of combustion & inlet air are mixing - further investigation is required. Check all flue components are correctly assembled, fixed & supported. Check the flue & terminal are unobstructed.

Is O

2  20.6% and

2 < 0.2% ?

TURN APPLIANCE OFF !

Call 0344 871 1525 for advice. The appliance MUST NOT be commissioned until all problems are identified and resolved.

Set Boiler to Maximum Rate

(see 10.1.11) Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser.

Perform Flue Integrity Combustion Check

Insert the analyser probe into the air inlet test point, allowing the reading to stabilise.

Is O

2  20.6% and

2 < 0.2% ?

Yes

Verify Integrity of Seals

Check all burner seals, internal flue seals, door & case seals. Replace any seals that appear unsound.

Is CO < 350ppm and CO/CO

2 ratio <

0.004 ?

Check CO & Combustion Ratio at Maximum Rate

Whilst the boiler is still

Yes

operating at maximum insert the analyser probe into the flue gas test point, allowing the reading to stabilise.

Is CO < 350ppm and CO/CO < 0.004 ?

Yes

10.0 Commissioning

10.2 Checking Combustion

1. Follow the flow chart opposite.

Set Boiler to Minimum Rate

(see 10.1.17)

2 ratio

Yes

Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser.

Check CO & Combustion Ratio at Minimum Rate

Whilst the boiler is operating at minimum insert the analyser probe into the flue gas test point, allowing the reading to stabilise.

TURN APPLIANCE OFF !

Call 0344 871 1525 for advice. The appliance MUST NOT be commissioned until all problems are identified and resolved. If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with the GSIUR. Note: Check & record the CO & combustion ratio at both maximum & minimum rates before calling 0344 871 1525.

Is CO < 350ppm and CO/CO

2 ratio <

0.004 ?

Yes

BOILER OPERATING

SATISFACTORILY. NO

FURTHER ACTION

REQUIRED

Ensure test points are capped, the boiler case front panel is correctly fitted & secured and all other commissioning procedures completed. Complete the ‘Benchmark’ Checklist, recording the CO & combustion ratio readings as required.

Central Heating

Temperature Control

Fig. 38

Domestic Hot Water Temperature Control

x 2

10.0 Commissioning

10.3 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. It is necessary to set the boiler to ‘Calibration Mode’.

Selector Switch

Reset

Gas Pressure

Test Point

Display

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Gas Valve

Fig. 39

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:-

25 model 2.76 m

30 model 3.17 m

Fig. 40

Fig. 43

Fig. 42

Fig. 44

Fig. 41

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.

11.0 Completion

11.1 Completion

Case Front Panel

1. Instruct the user in the operation of the boiler and system including the integral timer, 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. 45

12.0 Servicing

12 .1 Annual Servicing

Case Front Panel

Fig. 46

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 12.2.

• The operational gas inlet pressure as described in Section

10.3.1 to 10.3.7 and the gas rate as described in 10.3.8.

• The combustion performance as described in ‘Check the

Combustion Performance’ (12.1.4 to 12.1.6 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. 47

Condensate

Trap

Check the Combustion Performance (CO/CO

ratio)

4. Set the boiler to operate at maximum rate as described in Section 14.1.1 to 14.1.6.

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 12.2) &

re-check

• Adjust the gas valve (Section 14.0) & re-check

• Replace the gas valve (Section 13.23) & re-check

12.2 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. 46).

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. 47).

Fig. 48

5. Unscrew the sump from the bottom of the condensate trap

Sump

assembly (Fig. 48) and remove any deposits from the sump and trap. Clean as necessary and replace the sump.

Injector

Gas Pipe

Gas/Air Inlet

12.0 Servicing

12.2 Annual Servicing - Inspection (Cont)

6. Undo the nut on the gas pipe at the gas/air inlet (Fig. 49) and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector.

Fig. 49

Fig. 50

Fan Air Inlet Pipe

7. Disconnect the electrode lead caps, remove the strain relief clip from the sensing lead and disconnect the lead. Remove the fan electrical plugs and pull the sensing pipe off the fan.

8. Undo the screw securing the fan air inlet pipe to the bracket on the boiler top panel. Remove the pipe (Fig. 50).

9. Undo the five retaining nuts and washers and remove the fan, gas/air inlet and burner assembly (Figs. 51).

10. Carefully clean any debris from the heat exchanger.

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

12. Reassemble in reverse order.

DHW Filter

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

14. Initially check the cold water inlet tap filter.

Fig. 51

Fan, Gas/Air Inlet &

Burner Assembly

Hall Effect

Hydraulic Inlet

Assembly

Sensor

Restricter

Threaded Bush

Blanking

Cap

Fig. 52

Cold Water

Inlet Tap

15. Turn the tap off and draw off from a hot tap. Undo the blanking cap and remove the threaded bush (Fig. 52).

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

17. Pull off the Hall Effect sensor. Undo the restricter from the inlet/return manifold (Fig. 53).

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.

Fig. 53

Filter

Igniter

Igniter Feed

Plug

13.0 Changing Components

IMPORTANT: When changing components ensure that

both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler before recommissioning.

See Section 12.2 “Annual Servicing” for removal of case panel, door etc.

Electrode

Leads

Fig. 54

13.1 Igniter (Fig. 54)

1. Disconnect the igniter feed plug and the electrode leads, noting their positions.

2. Undo the nuts and screws securing the igniter to the boiler top panel. Remove the igniter.

3. Fit the new igniter and reassemble in reverse order.

13.2 Electrode Assembly (Fig. 55)

1. Disconnect the electrode lead caps, remove the strain relief clip from the sensing lead and disconnect the lead.

2. Undo the screws securing the electrode assembly to the combustion box panel and remove the assembly.

3. Check the condition of the sealing gasket and replace if necessary. Reassemble in reverse order.

Sealing Gasket

Fig. 55

Spark

Electrode

Leads

Injector

13.0 Changing Components

Gas/Air Inlet

13.3 Fan

1. Undo the nut on the gas pipe at the gas/air inlet (Fig. 56) and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector.

Fig. 56

Gas Pipe

Fig. 57

Fan Air Inlet Pipe

Gasket

2. Disconnect the electrode lead caps, remove the strain relief clip from the sensing lead and disconnect the lead. Remove the fan electrical plugs and pull the sensing pipe off the fan.

3. Undo the screw securing the fan air inlet pipe to the bracket on the boiler top panel. Remove the pipe (Fig. 57).

4. Undo the five retaining nuts and washers and remove the fan, gas/air inlet and burner assembly (Fig. 58).

5. Remove the air box and gasket from the fan and transfer to the new fan. Examine and replace the gasket if necessary.

6. Remove the four nuts and separate the fan from the gas/air inlet. Note the position of the orifice plate and examine the gasket, replacing if necessary (Fig. 58).

7. Fit the new fan, ensuring that the orifice plate is correctly fitted, and that the gasket is in position.

8. Examine the insulation around the burner and the heat exchanger gasket and replace if necessary.

9. Reassemble in reverse order, ensuring that the injector is in place and the sensing pipe is connected to the fan.

Gas/Air Inlet

Gasket

Orifice Plate

Fig. 58

13.4 Injector (Fig. 56)

1. Undo the nut on the gas pipe at the gas/air inlet and the gas valve. Remove the pipe.

2. Extract and replace the injector and reassemble in reverse order. Check the condition of the sealing washers, replacing if necessary.

Air Box

Gasket

Fan

13.0 Changing Components

13.5 Burner (Fig. 59)

1. 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. Also remove the injector.

2. Disconnect the electrode lead caps, remove the strain relief clip from the sensing lead and disconnect the lead. Remove the fan electrical plugs and pull the sensing pipe off the fan.

3. Undo the screw securing the fan air inlet pipe to the bracket on the boiler top panel. Remove the pipe.

4. Undo the five retaining nuts and washers and remove the fan, gas/air inlet and burner assembly.

5. Remove the electrode assembly and draw the insulation piece away. Undo the burner securing screws.

6. Fit the new burner and gasket, examine the insulation and heat exchanger gasket, replacing if necessary.

Electrode Assembly

Fig. 59

Burner

Insulation

7. Reassemble in reverse order.

13.6 Insulation (Fig. 59)

1. 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. Also remove the injector.

2. Disconnect the electrode lead caps, remove the strain relief clip from the sensing lead and disconnect the lead. Remove the fan electrical plugs and pull the sensing pipe off the fan.

3. Undo the screw securing the fan air inlet pipe to the bracket on the boiler top panel. Remove the pipe.

4. Undo the five retaining nuts and washers and remove the fan, gas/air inlet and burner assembly.

5. Remove the electrode assembly and draw the insulation piece away. Replace the insulation and reassemble in reverse order. Examine the heat exchanger gasket and replace as necessary.

Safety Thermostat

13.0 Changing Components

13.7 Safety Thermostat (Fig. 60)

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.

13.8 Central Heating Temperature Sensor (NTC)

(Fig. 61)

Fig. 60

Temperature Sensor

Fig. 61

Central Heating

1. Drain the boiler primary circuit. Pull the plug off the safety thermostat and disconnect the in-line plug in the sensor wire.

2. Unscrew the sensor from the heat exchanger. Reassemble the new sensor in reverse order, using a new sealing washer.

13.9 Water Pressure Sensor (Fig. 62)

1. Drain the boiler primary circuit.

2. Disconnect the plug from the sensor.

3. Unscrew the sensor from the hydraulic outlet assembly, examine the sealing washer and replace if necessary.

4. Reassemble in reverse order, ensuring that the plug is pushed fully onto the new sensor.

13.10 DHW Temperature Sensor (NTC) (Fig. 62)

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.

Pressure Sensor

3. Unscrew the sensor from the hydraulic outlet assembly. Examine the sealing washer,replacing if necessary.

4. Reassemble in reverse order. The plug will only fit one way.

Plate Heat Exchanger

Fig. 62

DHW Temperature

Sensor

Heat Exchanger

Air Vent

Grommet

13.0 Changing Components

13.11 Heat Exchanger Automatic Air Vent (Fig. 63 )

1. Drain the boiler primary circuit and unscrew the automatic air vent from the pump body.

2. Examine the ‘O’ ring seal, replacing if necessary, and fit it to the new automatic air vent.

3. Reassemble in reverse order, transferring the grommet to the new vent.

Fig. 63

Socket Headed

Screw

Pump Head

Pump Body

Fig. 64

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

13.12 Pump - Head Only (Fig. 64)

1. Drain the boiler primary circuit and disconnect the electrical plug from the pump motor.

2. Remove the socket head screws securing the pump head to the body and draw the head away.

3. Reassemble in reverse order.

13.13 Pump - Complete (Fig. 65)

1. Drain the boiler primary circuit and disconnect the electrical plug from the pump motor.

2. Undo the two screws securing the body to the pipe and manifold and draw the pump forwards.

3. Unscrew the automatic air vent from the pump body.

4. 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.

Automatic Air

Vent

13.14 Automatic Air Vent (Fig. 65)

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.

Fig. 65

13.0 Changing Components

Gauge Retaining

Fig. 66

Fig. 67

Hall Effect

Sensor

Bracket

Pressure Gauge

Capillary

13.15 Pressure Gauge (Figs. 66 & 67)

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.

13.16 Hall Effect Sensor (Fig. 68)

1. Ease the sensor upwards off the hydraulic inlet manifold assembly.

2. Disconnect the electrical plug from the sensor.

3. Connect the plug to the new sensor. Carefully fit the new sensor to the hydraulic assembly, ensuring it is fully down.

14.17 Pressure Relief Valve (Fig. 69)

Hydraulic Inlet

Assembly

Fig. 68

‘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. 69

Discharge Pipe

Grub Screw

Pressure Relief Valve

13.0 Changing Components

13.18 Plate Heat Exchanger (Fig. 70)

Plate Heat Exchanger

LH Location Stud

Fig. 70

Rubber Seal

1. Drain the boiler primary circuit and remove the gas valve as described in section 13.23.

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.

13.19 Diverter Valve - Motor Unit & Assembly

(Fig. 71)

Motor Unit

Multi-pin Plug

Valve

Assembly

Pressure Sensor

Fig. 71

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. 72

Control Box Cover

P.C.B.

13.0 Changing Components

13.20 P.C.B. (Figs. 72 & 73)

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.

3. Note the position of all plugs and wires on the P.C.B. and disconnect them.

4. Undo the securing screws and remove the P.C.B. Transfer the control knob drive pins to the new P.C.B. and turn them fully anticlockwise.

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

13.21 Pump P.C.B. (Figs. 72 & 73)

Selector

Switch

Pump P.C.B.

Facia

Selector Switch Knob

Fig. 73

Drive Pins

Temperature Control Knobs

1. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots.

2. Note the position of all plugs and wires on the P.C.B. and disconnect them. Undo the securing screws and remove the P.C.B.

3. Reassemble in reverse order.

13.22 Selector Switch (Figs. 72 & 73)

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.

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

13.0 Changing Components

Sensing Pipe

Power Lead

Fig. 74

Gas Valve

Earth Lead

Gas Feed

Elbow

Throttle

Adjustment Screw

13.23 Gas Valve (Fig. 74)

IMPORTANT: After replacing the valve the CO2must be checked and adjusted as detailed in Section 14.0 Setting the Gas Valve. Only change the valve if a suitable calibrated combustion analyser is available, operated by a competent - see section 12.1.

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

2. Remove the screws securing the gas valve to the boiler bottom panel.

3. Pull off the power lead, 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. Reassemble in reverse order., ensuring that all seals are in place and the injector is fitted.

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. 75). If the boiler

will not light, or the correct CO

cannot be achieved

contact the ‘heateam’ technical helpline.

Retaining Bracket

Boiler Chassis

Fig. 76

Spring

Washer

Lock Nut

Expansion Vessel

Fig. 75

12.24 Expansion Vessel (Fig. 76)

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 and spring washer 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.

Central Heating

Temperature Control

Selector Switch

Display

Fig. 77

Domestic Hot Water Temperature Control

x 2

14.0 Setting the Gas Valve

14.1 Setting the Gas Valve (CO2 check)

IMPORTANT: The CO2must be only be checked and 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 boiler for several minutes. To do this it is necessary to set the boiler to ‘Calibration Mode’.

) may be checked after running the

Reset

Fig. 80

Plug

Analyser Probe

Central Heating

Temperature Control

Fig. 78

Flue Adaptor Test

Point

bar

Domestic Hot Water Temperature Control

Fig. 79

Fig. 81 Fig. 82

Fig. 83

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

3. Turn both temperature control knobs fully anticlockwise,

then quickly turn the DHW temperature knob

/4clockwise

twice and back fully anticlockwise (Fig. 77).

4. The display will now alternate between ‘SF’ and the current boiler temperature and both green LEDs will flash (Figs. 78 &

79).

5. Turn the CH temperature 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 80, 81 & 82).

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

83).

The CO The CO

8. It is possible to alter the CO

should be 9.0% + 0.0 - 0.4 (25)

should be 9.1% + 0.0 - 0.4 (30)

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. 84). Turning clockwise will reduce the CO

Anticlockwise will increase th e CO

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.

Throttle

Adjustment Screw

(cover removed)

Reduce CO

at max. rate

Gas Valve

Fig. 84

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

9. The CO

must then be checked at minimum rate. Turn the CH temperature knob fully anticlockwise. As the knob is turned the display will change, indicating the fan speed. When the display reads ‘ 0’ the boiler runs at minimum rate.

The CO

10. With the boiler on minimum, the ‘Min. Rate’ adjustment

should be 8.4% + 0.0 - 0.4

screw must be altered, using a suitable hexagon key, after

removing the cap (Fig. 84). If the CO

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

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 DHW knob.

12. Check the Combustion Performance (CO/CO

ratio).

This must be less than 0.004.

Water Pressure Switch

15.0 Electrical

15.1 Illustrated Wiring Diagram

Central Heating NTC Sensor

DHW NTC Sensor

Hall Effect

Sensor

Overheat Stat

g/y

Fan

Pump

PCB

6 Way

Connector

Link

g/y

X400

9876

54321

910876

54321

X401

Integral Timer (where fitted)

Control PCB

X501

56789

Spark Generator

Ignition Electrode

1 234

1 2

1 234

g/y

Pump

Diverter Valve

Gas Valve

Mains Input Cable

br bk b w

- brown

- black

- blue

- white

- green

- green / yellow

g/y

- red

- greygr

313

304

426

16.0 Short Parts List

Short Parts List

Key G.C. Description Manufacturers

No. Part No.

No.

326 Fan 5121447

426 Motor 3 Way Valve 5132452

320 Electrode Assembly 5130293

422 Gas Valve 720301001

400

422

320

404

326

419

404 Hall Effect Sensor 5114767

313 Burner 5130292

419 Water Pressure Switch 5114748

400 Plate Heat Exchanger 248048

415 Pump 7222703

421 NTC Sensor DHW 5114725

420 Overheat Thermostat 5114729

304 NTC Sensor CH 5130291

504 Pressure Gauge 248090

503 PCB 25 5131264

PCB 30 5131265

505 Pump PCB 7222704

505

503

415

421

420

504

17.0 Fault Finding

17.1 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.

17.2 Error Codes

Table Of Error Codes

E20 E28 E50 E110 E119 E125 E133 E160

Central Heating NTC Fault Incorrect PCB Fitted Hot Water NTC Fault Safety Thermostat Operated Water Pressure Switch Not Operated Circulation Fault (Primary Circuit) Interruption Of Gas Supply or Flame Failure Fan or Fan Wiring 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.

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 & 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 (do

17.0 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

3-way valve is open to Central

Heating circuit

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

Go to section ‘K’

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’

YES

Error 125 flashing

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

Ensure that primary

circulation is OK & that

there is no blockage

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

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

Check the Central Heating

NTC sensor

Go to section ‘E’

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

17.0 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

17.0 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:

X3 Connection Pump PCB

YES

X2 Connection Pump PCB

YES

X1 Control PCB

YES

X3 Control PCB, T3, T4

YES

X1 Pump PCB

YES

Replace Pump

Check wiring

Check incoming wiring

Replace Pump PCB

Check wiring

Replace Control PCB

Replace Pump PCB

Display illuminated

Replace PCB

CH system pressure less than 0.5 bar Re-pressurise system

Check the tap of the automatic air vent is opened

1. Fan connections correct at fan. PCB -

X2 connector, is 230V AC across terminals 5 & 7

YES

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

YES

Open the automatic air vent

Fan jammed or faulty winding

Replace PCB

YES

Replace water pressure switch

YES

Replace fan

17.0 Fault Finding

E20 or E50 - Temperature sensors faulty. Cold resistance approximately 10k @ 25° C (DHW and CH sensors) 20k @ 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

voltage at PCB - X2 connector is 110V AC across terminals 2 & 5

YES

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

Replace PCB

YES

Replace Hall Effect Sensor

Replace PCB

Replace igniter

17.0 Fault Finding

Check supply pressure at the

gas valve:-

Minimum 17 mbar

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 10k @ 25° C (CH 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

18.0 Notes

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

Competent Persons Scheme. A Building Regulations Compliance

will then be issued to the customer.

www.centralheating.co.uk

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 t

o 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.

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

Customer name: Telephone number:

Address:

Boiler make and model:

Boiler serial number:

Commissioned by (PRINT NAME): Gas Safe register number:

Company name: Telephone number:

Company address:

Commissioning date:

CONTROLS (tick the appropriate boxes)

Time and temperature control to heating

Room thermostat and programmer/timer Programmable room thermostat

Load/weather compensation Optimum start control

Time and temperature control to hot water Cylinder thermostat and programmer/timer Combination Boiler

Heating zone valves Fitted Not required

Hot water zone valves Fitted Not required

Thermostatic radiator valves Fitted Not required

Automatic bypass to system Fitted Not required

Boiler interlock Provided

ALL SYSTEMS

’s instructions Yes

What system cleaner was used?

What inhibitor was used? Quantity litres

Yes N o

CENTRAL HEATING MODE measure and record:

Gas rate m³/hr OR ft³/hr

Burner operating pressure (if applicable) mbar OR Gas inlet pressure mbar

°C

Central heating return temperature °C

COMBINATION BOILERS ONLY

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

Yes N o

DOMESTIC HOT WATER MODE Measure and Record:

Gas rate m³/hr OR ft³/hr

Burner operating pressure (at maximum rate) mbar OR Gas inlet pressure at maximum rate mbar

Cold water inlet temperature °C

Hot water has been checked at all outlets Yes Temperature °C

I/min

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes

ALL INSTALLATIONS

Record the following:

At max. rate: CO ppm AND CO/CO

Ratio

At min. rate: (where possible) CO ppm AND CO/CO

Ratio

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

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

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

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

Commissioning Engineer’s Signature

Customer’s Signature

www.centralheating.co.uk

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.

SERVICE RECORD

SERVICE 01

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 02

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 03

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 04

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 05

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 06

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 07

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate: (Where Possible) CO ppm AND CO² %

Comments:

Signature

SERVICE 08

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate: (Where Possible) CO ppm AND CO² %

Comments:

Signature

SERVICE 09

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 10

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

*All installations in England and Wales must be

to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance

will then be issued to the customer.

Baxi Customer Support

0344 871 1525

Opening hours

Monday - Friday, 8.00am-6.00pm Weekends and Bank Holidays, 8.30am-2.00pm

Please note calls may be recorded for training and monitoring purposes

baxi.co.uk

www.baxi.co.uk/registration

For the warranty to be maintained, please make sure...

Benchmark checklist is completed

Warranty is registered with Baxi

The boiler has an annual service

For full terms and conditions, visit www.baxi.co.uk/terms. Failure to adhere to terms and conditions will void your manufacturer’s warranty.

Baxi Brooks House, Coventry Road, Warwick, CV34 4LL

Please ensure the boiler is installed in accordance with these installation instructions and that you adhere to the Building Regulations.

e&oe All descriptions and illustrations provided in this document 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.

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