Main System 28 Eco, System 24 Eco Installation Manual

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Installation & Service Instructions

System Eco

Range

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

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Natural Gas

Main System 24 Eco

G.C.No41 467 11

Main System 28 Eco

G.C.No41 467 12

© Baxi Heating UK Ltd 2011 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner, except for permitted fair dealing under Copyrights, Designs and Patents Act 1988.

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

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

Full acknowledgement of author and source must be given.

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

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.

0086

ISO 9001

FM 00866

Building Regulations and the Benchmark Commissioning

Checklist

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

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

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

With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn.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

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

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

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

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Installer Notification Guidelines

Choose Building

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Regulations Notification

Route

Competent Person's

Self Certification Scheme

Install and Commission this appliance to manufacturer's

instructions

Complete the

Benchmark Checklist

If you notify via the ‘Gas Safe

the Building Regulations

certificate on members’ behalf

Building Control

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact a government approved

inspector

Install and Commission this appliance to manufacturer's

instructions

Scheme Members only

Call ‘Gas Safe Register’ on:

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

Legislation

Codes of Practice - refer to the most recent version

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

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

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

• Gas Safety (Installation & Use) Regulations.

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

• The Water Fittings Regulations or Water Byelaws in Scotland.

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

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

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

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

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 0087.

Product/Production certified by: Notified Body 0086.

For GB/IE only.

IMPORTANT - Installation, Commissioning, Service & Repair

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

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

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

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

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

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

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

In GB the following Codes of Practice apply: Standard Scope

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

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

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

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

central heating systems.

In IE the following Codes of Practice apply: Standard Scope

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

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

heating systems. BS 7074 Expansion vessels and ancillary equipment for

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

central heating systems.

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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 !!

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CONTENTS

1.0 Introduction 7

2.0 General Layout 8

3.0 Appliance Operation 9

4.0 Technical Data 10

5.0 Dimensions and Fixings 11

6.0 System Details 12

7.0 Site Requirements 14

8.0 Flue Options 18

9.0 Plume Displacement 23

10.0 Installation 27

11.0 Commissioning 33

12.0 Completion 35

13.0 Servicing 36

14.0 Changing Components 38

15.0 Setting the Gas Valve 46

16.0 Electrical 47

17.0 Short Parts List 48

18.0 Fault Finding 49

Benchmark Checklist 54

Section Page

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1.0 Introduction

1.1 Description

1. The Main System Eco is a fully automatic gas fired wall mounted condensing system boiler. It is room sealed and fan assisted.

2. The boiler is set to give a maximum output of :-

24 models - 25.94 kW

26.95 kW (Condensing)

28 models - 28.63 kW

30.20 kW (Condensing)

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

4. The boiler incorporates a circulating pump and expansion vessel. It is suitable for use only on fully pumped sealed systems.

5. The boiler data badge gives details of the model, serial number and Gas Council number and is situated on the front sloping face of the hydraulic plate. It is visible when the case front panel is removed and the control box hinged down (Fig. 1 & 1a).

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

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

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

9. All systems must be thoroughly flushed and treated with

inhibitor (see section 6.1).

1.2 Contents of Pack

1. Boiler Unit

2. Wall Plate (inc. taps)

3. Set of Pipes (inc. nuts)

4. Template & ‘Quick Fit’ Guide

5. Literature Pack

Fig. 1

Control Box

Case Front Panel

Information Label

Data Badge

Fig. 1a

Facia Door

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2.0 General Layout

2.1 Layout

1. Expansion Vessel

2. Automatic Air Vent

3. Primary Return Temperature Sensor

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. Gas Valve

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. Calibration 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. Calibration Mode Light

27. Display

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Reset

bar

3.0 Appliance Operation

10 12 11

Key

1 Heat Exchanger 2 Burner 3 Ignition Electrode 4 Flame Sensing Electrode 5 Gas Valve 6Pump 7 Automatic Air Vent 8 Pressure Relief Valve 9 Boiler Drain Point 10 Gas Inlet 11 Boiler Flow 12 Boiler Return 13 Pressure Gauge 14 Automatic By-Pass 15 Water Pressure Sensor 16 Safety Thermostat 17 Temperature Sensor 18 Expansion Vessel 19 Return Temperature Sensor 20 Fan

Boiler Primary Circuit

Fig. 2

3.1 Operating Mode (Fig. 2)

1. With a demand for heating or hot water, the pump circulates water through the primary circuit. If the pressure is at least 0.5 bar and the ignition sequence will start.

2. 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.

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

IMPORTANT: When the selector switch is in the ‘0’ (Off) position the electrical supply to the boiler is isolated. The boiler will not operate.

3.2 Frost Protection Mode

1. The frost protection mode is integral to the appliance and functions when the selector switch (see Section 2.1) is in the ON 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.

3.3 Pump Protection

1. With the selector switch (see Section 2.1) in the ON position ( ) the pump will automatically operate for 1 minute in every 24 hours to prevent sticking.

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4.0 Technical Data

4.1 System 24 & 28 Eco

Flue Terminal Diameter 100mm Dimensions Projection 125mm

Outercase Dimensions

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

Weights

Packaged Boiler Carton 51.1 kg (24 &28) Installation Lift Weight 44.5 kg (24 & 28)

Central Heating Primary Circuit Pressures

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

Pump

Available Head See graph below

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

bar

Min Pre-charge Pressure 0.5

(18,24) (27) Max Capacity of litre litre CH System 125 155

Primary Water Content of Boiler (unpressurised) 2.5 2.8

Connections copper tails Gas Supply - 22mm Central Heating Flow - 22mm Central Heating Return - 22mm Pressure Relief Discharge - 15mm

Temperatures

C.H. Flow Temp

(adjustable)

25°C to 80°C max (± 5°C)

NOxClass 5

Clearances Above Casing 200 mm Min

300 mm Min (80/125mm flue) Below Casing 200 mm Min Front 450 mm Min

(For Servicing)

Front 5 mm Min (In Operation) L.H. Side 5 mm Min R.H. Side 5 mm Min

(In Operation)

Heat Input CH (Net) Max Min

24 model kW 26.06 7.82

28 model kW 29.32 8.8

Heat Output CH (Non-Condensing)

Max Min

24 model kW 25.94 7.61

28 model kW 28.63 8.56

Electrical Supply 230V~ 50H

(Appliance must be connected to an

earthed supply)

Power Consumption

150W

Electrical Protection

IPX0D (with timer) IPX4D (without timer)

Internal Fuse Rating F2L

Appliance Category CAT I

Inlet Pressure (Natural Gas - G20)

mbar 20

Injector (Natural Gas - G20)

6.0mm (24 & 28 models)

Appliance Type C

Heat Output CH (Condensing)

Max Min

24 model kW 26.95 8.37

28 model kW 30.20 9.42

Max Gas Rate (Natural Gas - G20)

(After 10 mins)

24 model m3/h 2.76

28 model m3/h 3.10

Condensate Drain

To accept 21.5mm (

/4in) plastic waste pipe

Heat Input CH (Gross) Max Min

24 model kW 28.92 8.68

28 model kW 32.54 9.77

External Fuse Rating 3A

SAP 2005 Seasonal Efficiency for 24 models

is 91.1%

SAP 2005 Seasonal Efficiency for 28 models

is 90.2%

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of

dwellings. The test data from which it has been

calculated has been certified by 0087.

SEDBUK Declaration

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5.5

4.5

3.5

2.5

Metre (wg)

1.5

0.5

Pump - Available Head (24,27)

200 400 600 800 1000 1200 1400

Flow Rate (l/h)

5.0 Dimensions and Fixings

Tap Rail

360° Orientation

Tube Ø 100mm

Heating

Return

(22mm)

Heating

Flow

(22mm)

Pressure Relief

Valve

(15mm)

Gas

Inlet

(22mm)

130 mm

65 mm

Condensate

Drain

127 mm

Dimensions

A 780mm

B 345mm

C 450mm

D 116mm Ø Min.

F 145mm

G 132mm

210mm (80/125)

H 225mm

At Least 1.5

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6.0 System Details

6.1 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.

6.2 Bypass

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

6.3 System Control

1. For optimum operating conditions, the heating system into which the boiler is installed should include a control system.

2. Such a system will comprise of a timer control and separate room or cylinder thermostats as appropriate.

3. The boiler should be controlled so that it operates on demand only.

4. Operation of the system under control of the boiler thermostat & TRV’s only does not produce the best results.

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6.0 System Details

6.5 System Filling and Pressurising (Fig. 6)

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

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

4. The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe, provided a ‘Listed’ double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use.

6.6 Expansion Vessel (Central Heating only)

1. The appliance expansion vessel is pre-charged to 0.5 bar. Therefore, the minimum cold fill pressure is 0.5 bar. The vessel is suitable for correct operation for system capacities up to 125 litres (18, 24) 155 litres (27). 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. 7)

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

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

3. The discharge must not be above a window, entrance or other public access. Consideration must be given to the possibility that boiling water/steam could discharge from the pipe.

Fig. 6

Fig. 7

Stop Valve

Double Check Valve

DHW Mains Inlet

CH Return

Temporary Hose

Pressure Relief Valve

Discharge Pipe

Stop Valve

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7.0 Site Requirements

7.1 Location

1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (The boiler may be fitted inside a cupboard-see Section 7.3).

2. If the boiler is sited in an unheated enclosure then it is recommended to leave the ON/OFF Selector Switch in the domestic hot water and central heating position to give frost protection.

3. If the boiler is fitted in a room containing a bath or shower reference must be made to the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of I.S. 813 “Domestic Gas Installations” and the current ETCI rules.

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

7.2 Clearances (Figs. 8 & 9)

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

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

200mm Min

800mm

450mm

5mm Min

450mm Min

For Servicing

Purposes

Fig. 8

Fig. 9

In Operation

5mm Min

200mm Min

(300mm Min if

using 80/125mm

flueing system)

At Least 1.5°

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7.0 Site Requirement

7.3 Ventilation of Compartments

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

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

7.4 Gas Supply

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

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

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

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

7.5 Electrical Supply

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

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

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

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

3. When the system includes an indirect domestic hot water cylinder it is recommended that a cylinder thermostat is used in conjunction with a 3 port 2 position valve or 2 port zone valve.

7.6 Bath & Shower Rooms

1. If the boiler is fitted in a room containing a bath or shower and NOT FITTED with any optional integral timer or thermostat, it can be fitted in zone 2, (Figs. 11 & 12 show 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. 10

Gas Service Cock

Zone 2

Zone 1

Zone 0

Zone 2

Window Recess

0.6 m

Ceiling

Outside Zones

Zone 2

Zone 1

Zone 0

2.25 m

Window Recess Zone 2

0.6 m

Fig. 11

Fig. 12

In GB Only

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7.0 Site Requirements

7.7 Condensate Drain

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

The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre) along the entire run.

1. The condensate outlet will accept 21.5mm (3/4in) plastic overflow pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain is acceptable.

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

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

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

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

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

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

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

should use 32mm waste pipe.

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

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

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

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

Boiler

2.5° Minimum fall

Termination to an internal soil and

vent pipe

450mm min

Boiler

2.5° Minimum fall

External termination via internal discharge

branch

e.g sink waste - downstream

Sink

Pipe must terminate above water level but below surrounding surface

Boiler

Pipe must terminate above water level but below surrounding surface

2.5° Minimum fall

Termination to a drain or gully

Boiler

500mm min

2.5° Minimum fall

Termination to a purpose made soak-

away

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

50mm per metre of pipe run

Fig. 13

Fig. 14

Fig. 15

Fig. 16

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7.0 Site Requirements

7.8 Flue (Figs. 17 & 18)

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

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

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

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

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

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

IMPORTANT:

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

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

Fig. 18

Fig. 17

300 min

Terminal Assembly

Top View Rear Flue

Property Boundar y Line

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

Opening Window or Door

150mm MIN.

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

Fig. 18a

Plume Displacement Kit

Air Inlet

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

Directly below an opening, air brick, opening windows, etc. 300

Above an opening, air brick, opening window etc. 300

Horizontally to an opening, air brick, opening window etc. 300

Below gutters, soil pipes or drain pipes. 25

Below eaves. 25

Below balconies or car port roof. 25

From a vertical drain pipe or soil pipe. 25

From an internal or external corner. 25 I Above ground, roof or balcony level. 300 J From a surface or boundary line facing a terminal. 600 K From a terminal facing a terminal (Horizontal flue). 1200

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

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

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

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 B.S.5440-1.

Supplied by HeatingSpares247.com

J,K

D E

J,K

Likely flue positions requiring a flue terminal guard

8.0 Flue Options

8.1 Horizontal Flue Systems

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

2. Maximum permissible equivalent flue lengths are:-

(60/100) (80/125)

Horizontal Concentric 10 metres 20 metres

3. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes: 135° bend 0.5 metres

93° bend 1.0 metres

Twin Flue Pipe 135° bend 0.25 metres

91.5° bend 0.50 metres

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

NOTE: Flue length is measured from point (i) to (ii) as shown.

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

Horizontal Flues

(ii)

(i)

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.

(ii)

(i)

This bend is equivalent to 1 metre

Total equivalent length =

A+B+C+2x90°Bends

This bend is equivalent to 1 metre

Supplied by HeatingSpares247.com

8.0 Flue Options

Vertical Flues

Vertical Flues (Twin Pipe)

(ii)

(i)

(ii)

(i)

8.2 Twin & Vertical Flue Systems

1. Maximum permissible equivalent flue lengths are:-

(60/100) (80/125)

Vertical Concentric 10 metres 20 metres

(80/80)

Twin Pipe 20 metres

3. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes: 135° bend 0.5 metres

93° bend 1.0 metres

Twin Flue Pipe 135° bend 0.25 metres

91.5° bend 0.50 metres

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

NOTE: Flue length is measured from point (i) to (ii) as shown.

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

The total equivalent length for this example is

= 6.5 metres.

1m extension

135°bend

91.5°bend

0.25m

0.5m

5.0m

0.5m

1.0m

AIR DUCT

fittings/pipes

Sub total

Equivalent

Length Value

Equivalent Length Air Duct = 6.5m

1m extension

135°bend

91.5°bend

0.25m

0.5m

5.0m

0.5m

1.0m

FLUE DUCT

fittings/pipes

Sub total

Equivalent

Length Value

Equivalent Length Flue Duct = 6.5m

(ii)

(i)

Roof

Terminal

This bend is equivalent to 1 metre

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

All vertical and angled runs must be included, measured from the boiler adaptor point (i) to the joint with the flue terminal point (ii). One 91.5° bend or two 135° bends can be included without reduction of the flue length.

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

1 metre for each 91.5° bend

0.5 metre for each 135° bend

300mm Min

Apart

1m Min

20m Max

Supplied by HeatingSpares247.com

8.0 Flue Options

K,K1

U,W

8.3 Flue Accessories

Key Accessory Size Code No

FLUE GROUP A Concentric Flue System 100mm diameter

A3 Telescopic Internal Flue Kit 315-500mm 5119654 A2 Telescopic Flue (incl elbow) 5118069 A Horizontal Flue Terminal (incl elbow) 5118489 B Flue Extension 1000mm 5111074 C Flue Bend 93° 5111075 D Flue Bend (pair) 135° 5111085 U Pipe Support (painted) 100mmØ 5111080 P Wall Liner 5111067 S Flue Terminal Deflector 5111068

FLUE GROUP N Twin Flue System 80mm diameter

E Flue Extension (pair) 1000mm 5111087 F Flue Bend (pair) 90° 5111072 G Flue Bend (2 pair) 135° 5111086 J Vertical Flue Boiler Adaptor Kit 720089801 H Vertical Flue Adaptor 5111084 Y Flue Horizontal Terminal Kit 5120172 W Pipe Support (pair) 80mm 5111081

FLUE GROUP G Flue System 80/125mm diameter

A4 Horizontal Flue Kit 5118580 B Straight Extension Kit 1000mm 5118584 D Bend Kit (pair) 135° 5118597 C Bend 91.5° 5118588 R Vertical Flue Adaptor 5111070

FLUE GROUP A, N, G Vertical Flue Kits

K Vertical Flue Terminal

(use with Group G) 5111078

K1 Vertical Flue Terminal

(use with Group A) 5118576

L Pitch Roof Flashing 5122151 M Roof Cover Plate 246143 N Flat Roof Flashing 246144

Supplied by HeatingSpares247.com

8.0 Flue Options

8.4 Twin Flue Duct Adaptor

1. The kit allows connection of a twin flue system to the boiler adaptor.

8.5 Twin Flue Connection

1. Engage the twin flue duct adaptor in the boiler adaptor, making sure that it is pushed down as far as possible.

2. Ensure that the air & flue ducts are connected correctly and that they are adequately supported (at least once every metre using the available pipe supports).

3. Ensure that all joints and elbows are fully engaged and cannot become disconnected during operation.

Flue Duct Connection

Air Duct Connection

Supplied by HeatingSpares247.com

8.0 Flue Options

Fig. 19

100mm 685mm

8.6 For Roof Terminals

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

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

IMPORTANT: If the boiler is not fitted immediately after the flue system, temporary precautions must be taken to prevent rain entry into the room of installation. Any precautionary measures must be removed prior to commissioning the boiler.

8.7 Flue Dimensions

The standard horizontal flue kit allows for lengths between 100mm and 685mm from elbow to terminal (Fig. 19).

The maximum permissible equivalent flue length is:

10 metres (60/100 system) 20 metres (80/125 system)

8.8 Flue Trim

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

8.9 Terminal Guard (Fig. 20)

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

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

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

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

8.10 Flue Deflector (Fig. 21)

1. If required, push the flue deflector over the terminal end and rotate to the optimum angle for deflecting plume. Secure the deflector to the terminal with screws provided.

Fig. 20

Flue Extension

Air Duct

Flue Duct

Cut the same amount off the Air Duct & Flue Duct

Approx

1425mm

Flue Deflector

Fig. 21

Supplied by HeatingSpares247.com

9.0 Plume Displacement

9.1 Plume Displacement Kit (Fig. 23)

Kit No 5118638

Content of kit

1 0.9m 60/100 Concentric Flue 1 1m 60 Dia Exhaust Flue Pipe 1 Adaptor 2 60 Dia Support Brackets 1 93° Elbow/Plume Outlet Assembly 1 Flexible Flue Trim 3 “O” Rings 1 ‘Jubilee Clip 1 Elbow

1. This kit is recommended for installations where the condensate plume emitted from the flue may cause a nuisance or affect the surroundings.

2. The terminal must be positioned outside the building with the air inlet facing downward and outlet connection upwards.

3. The plume outlet must always be at least 45° to the wall, with the ‘peak’ uppermost to prevent rain entry (Figs. 24 &

25), and be at least 2 metres above ground level. It must be secured as shown in Fig. 18a. The plume outlet must also be at least 500mm from the air inlet in any direction (Fig. 25).

NOTE: The outlet must be positioned so that any condensate plume is directed away from adjacent surfaces. There must be a constant fall along the entire length of the flue system from the outlet back to the boiler.

4. It is possible to reduce or increase (with the addition of extensions) the length of either or both the 60/100 concentric and 60Ø exhaust.

5. Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly.

6. The minimum length of the concentric flue is 100mm when measured from the edge of the flue elbow.

IMPORTANT: The maximum equivalent length of concentric flue is:- 8 metres Additional bends may be fitted in the concentric flue, but the equivalent length must be reduced by 1 metre (93° elbow) or 0.5 metres (45° elbow).

7. 60Ø 1 metre extensions (including support bracket), and additional 93° & 45° elbows are available. Any additional 93° & 45° elbows must be accounted for when calculating flue lengths.

NOTE: Permitted positions of the plume outlet relative to doors, windows etc. are the same as for conventional concentric flues as detailed in the main Installation & Servicing Instructions and BS5440 Pt. 1. It is NOT necessary to fit a terminal guard over the air inlet or the plume outlet.

Air Inlet at Bottom

‘Peak’ Uppermost

Fig. 24

Fig. 25

500mm Min.

45°

Outlet must be at least 45° from wall face

93° Elbow/Plume Outlet Assembly

60Ø Exhaust Flue Pipe

60Ø Support Bracket

Flexible Flue Trim

60/100Ø Concentric Flue

Adaptor

O Ring

‘Jubilee’ Clip

0.9 metres

Fig. 23

Fig. 22

Elbow

Supplied by HeatingSpares247.com

9.0 Plume Displacement

Concentric 60/100 Flue

60Ø Exhaust

Fig. 26

Fig. 27

Flue Length - Worked Example Main System 28 Eco

In Fig. 27 opposite an additional 93° elbow and pair of 45° elbows have been included in the 60Ø exhaust. Also 3 straight extension pieces have been used.

To calculate total length:Length of 60Ø supplied in kit = 1 metre 3 x 1 metre Extensions = 3 metres 1 x 93° Elbow = 1 metre 2 x 45° Elbow = 1 metre (0.5 metres each)

Total 60Ø = 6 metres

After consulting the table in Example 3 it can be determined that the concentric flue could be up to approximately 2.3 metres long.

Concentric Flue

Support Bracket

45° Elbow

93° Elbow

1 metre Extension

1 metre supplied in kit

Additional Accessories

93° Elbow 5121639 45° Elbow (Pair) 5121370 1 metre 60Ø Extension 5121638

9.2 Determining Permissible Lengths

In the graph the solid line diagonal represents the relationship between the concentric flue assembly (and any extensions) and the 60Ø exhaust (and any extensions or additional bends).

Example 1 - Not Permissible

If, for instance, a concentric length of 5 metres was required and the 60Ø exhaust needed to be 12 metres the graph shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line.

Example 2 - Flue Lengths OK

Where both lengths have been determined they can be applied to the graph to check that the installation is permissible. For example, if it was known that 2 metres of concentric flue and 4 metres of 60Ø exhaust were required, the values could be applied to the graph as shown in Example 2. As the point of intersection of the dotted lines is below the solid diagonal line, the combination of lengths is shown to be acceptable.

Example 3 - Flue Lengths OK

In the example shown, assume that the concentric part of the flue needs to be 2.3 metres long. Find the position of ‘2.3’ on the horizontal axis of the graph and then project upwards to the solid diagonal line. This is represented by the vertical thick dotted line. Where this dotted line intersects with the solid diagonal line on the graph, project across to the vertical axis. As can be seen this corresponds with 6 metres. Therefore, the total equivalent length of the 60Ø exhaust can be up to 6 metres. Any elbow equivalencies must be accounted for i.e. 93° elbows are equal to 1 metre, each 45° elbow to 0.5 metres.

60 Ø Exhaust (metres) X

Concentric 60/100 Flue (metres) Y

34 65798

60 Ø Exhaust (metres) X

34 65798

Example 1

Flue Lengths - Not Permissible

Example 2

Flue Lengths - OK

Example 3

Flue Lengths - OK

Supplied by HeatingSpares247.com

60 Ø Exhaust (metres) X

34 65798

Concentric 60/100 Flue (metres) Y

9.0 Plume Displacement

Min. 2 metres

Fig. 28

Fig. 33

30mm

Fig. 30

Fig. 32

Fig. 31

Adaptor

Flue Trim

Position of ‘Jubilee’ Clip screw

Fig. 29

Spigot

9.3 General Fitting Notes

1. Cut a hole in the external wall which the concentric flue assembly will pass through. The hole should allow the flue to fall back to the boiler at an angle of at least 1.5°.

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

3. Measure and cut to size the concentric assembly and any extensions that are being used.

4. Insert the concentric assembly through the hole from outside the building.

5. If required, the flexible flue trim should be fitted prior to this as it cannot be fitted after. Use the large ‘Jubilee’ clip to secure the trim to the flue (See Fig. 29, trim shown dotted), with the screw part of the clip at the bottom.

6. Connect any extensions or elbows that are being used to the concentric assembly. Engage the extension, elbow or concentric assembly in the boiler flue elbow. Fit the boiler flue elbow to the boiler adaptor.

7. Ensure that the concentric assembly and any extensions fall back to the boiler at an angle of at least 1.5° and that the external air inlet is to the bottom.

8. Use suitable brackets to support the concentric assembly and any extensions, and make good inside and outside.

9. The 60Ø exhaust can now be fitted. Slide the adaptor over the plain end of the 60Ø exhaust (Fig. 31) and engage the exhaust in the terminal. Slide the adaptor down over the spigot. Mark and drill the adaptor, using a 2mm bit, as shown in Fig. 30. Secure the adaptor to the spigot using one of the screws supplied.

10. If it is necessary to shorten the 60Ø exhaust or any of the extensions, the excess material must be cut from the plain end of the pipe.

11. Determine the position of the 60Ø exhaust and mark on the wall a suitable position for the support bracket. If extensions are being used, a support bracket is supplied in each kit.

12. Drill the wall, and fit the bracket(s) using the plug and screw provided.

13. Mark and drill the 60Ø exhaust, using a 2mm bit, as shown in Fig. 32. Complete the installation of the 60Ø exhaust, securing in the brackets.

14. Fit the 93° elbow/plume outlet and secure with the two remaining screws supplied. Ensure the plume outlet is at least 45° to the wall and that the ‘peak’ is uppermost (Fig. 33).

Supplied by HeatingSpares247.com

50mm

30mm

9.0 Plume Displacement

9.3 General Fitting Notes (cont.)

15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air.

16. It is also possible to separate the plume outlet from the 93° elbow to allow the flue to be installed as shown in Fig. 34.

17. To do this, first slacken the two screws retaining the plume outlet to the elbow, and remove the outlet (Fig. 35). The elbow can now be used to connect the vertical to horizontal 60Ø exhaust (Fig. 34). Retighten the screws in the elbow.

18. The outlet can now be fitted into the female end of an 60Ø extension piece. It must be secured using two of the screws supplied in the bag with the ‘Jubilee’ clip.

19. Mark the female end of the extension at 30mm as shown in two positions, directly opposite each other (Fig. 36).

20. Using a suitable bit (e.g. 2mm), drill through the extension and outlet. Secure using two of the screws supplied.

21. The remaining screw must be used to secure the adaptor to the concentric terminal.

22. When the plume outlet is positioned under a balcony or other projection (Fig. 37) it must protrude at least 200mm (it is not necessary to extend it further than this).

23. When under balconies or projections it is permissible to rotate the concentric flue length up to 70°, clockwise or anti-clockwise (Fig. 38), if there is insufficient space to connect vertically.

24.This will allow the connection of the exhaust to the outlet spigot.

25. All other minimum & maximum dimensions must be adhered to, and the air inlet positioned such that it will not be subject to rain entry.

30mm

Fig. 35

Fig. 36

Fig. 34

Fig. 37

Plume Outlet

Elbow

Fig. 38

Outlet Spigot

Concentric Flue Length (shown end-on)

Supplied by HeatingSpares247.com

500mm Min.

200mm Min.

70°

10.0 Installation

10.1 Unpacking & Initial Preparation

The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4).

1. Remove staples, open flaps and remove cardboard sheet. Remove the polystyrene side pieces and literature. Two people can then lift out the boiler (Fig. 39).

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

3. Mark the position of the two most suitable fixing slots for the wall plate and boiler lower fixing holes. It is preferable to use the vertical fixing slots.

4. Mark the position of the centre of the flue hole (rear exit). For side flue exit, mark as shown (Fig. 40).

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

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

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

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

99. Connect the gas and water pipes to the valves on the wall plate using the copper tails supplied. Ensure that the sealing washers are fitted between the connections.

10.2 Flushing

1. Connect a tube to the central heating flow or return pipe (Fig. 41).

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

Fig. 41

145mm

For Side Flue Exit

Central Heating Return

Flushing Tube

Wall Plate

Fig. 40

Fig. 39 Unpacking Procedure

Supplied by HeatingSpares247.com

10.0 Installation

10.3 Fitting The Boiler

1. Lift the boiler using the Lifting Points as shown by the shaded areas (Fig. 43). The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig. 42) (see Safe Manual Handling page 5).

2. Ease the boiler forwards and remove the sealing caps from the boiler connections (Fig 43).

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

3. Insert the sealing washers between the valves and pipes

on the wall plate and the boiler connections. The rubber washers must be used on the gas connection.

4. Tighten all the connections.

10.4 Fitting the Pressure Relief Discharge Pipe

(Fig. 44)

1. Remove the discharge pipe from the kit.

2. Determine the routing of the discharge pipe in the vicinity of the boiler. Make up as much of the pipework as is practical, including the discharge pipe supplied.

3. The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building. See section 6.7 for further details.

4. Utilising one of the sealing washers, connect the discharge pipe to the adaptor and tighten the nut.

5. Complete the discharge pipework and route it to the outside discharge point.

IMPORTANT: Make all soldered joints before connecting to the pressure relief valve.

10.5 Condensate Drain (see Section 7.7)

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

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

2. The connection will accept 21.5mm (

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

Fig. 44

Pressure Relief Valve

Wall Plate

Discharge Pipe

Suggested Lifting Points

shown as shaded area

Fig. 43

Remove Sealing Caps from under the Boiler

Supplied by HeatingSpares247.com

10.0 Installation

Fig. 45

10.6 Fitting The Flue

HORIZONTAL FLUE

1. The standard flue is suitable for lengths between 100mm minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (Fig. 45).

2. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (Fig. 47).

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

3. Measure the distance from the outside wall face to the elbow. This dimension will be known as ‘X’ (Fig. 48).

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

IMPORTANT: Check all dimensions before cutting.

5. Mark dimension ‘Y’ on the flue as shown (Fig. 49). Carefully cut the waste material from the flue, ensuring that the ducts are square and free from burrs.

Fig. 49

Wall Thickness

(X)

Wall Thickness

(X)

Flue Elbow

Fig. 47

Adaptor

Apply Lubricant for ease of assembly.

Ensure Elbow is fully engaged into Boiler Adaptor

Fig. 48

Flue

Waste

100mm 685mm

Supplied by HeatingSpares247.com

10.0 Installation

Slots at bottom

Inner Flue Support Bracket

Fig. 50

Fig. 51

Fig. 52

Apply Lubricant for ease of assembly.

Ensure Flue is fully engaged into Flue Elbow

10.6 Fitting the Flue (Cont)

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

7. Take the inner flue support bracket (if not already fitted) and engage it over the flue duct. This will centralise the flue and air ducts, and ease assembly (Fig. 51).

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

9. Draw the flue back through the wall and engage it in the elbow. It may be necessary to use soap solution or similar to ease assembly of the elbow adaptor and flue (Fig. 51).

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

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

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

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

Supplied by HeatingSpares247.com

10.6 Fitting the Flue (Cont)

CONCENTRIC VERTICAL FLUE

15. Once the length of the vertical concentric extension has been determined mark and carefully cut off the excess material. The cut end MUST be square and free of burrs to ensure correct insertion into the boiler adaptor.

16. Measure 25mm from the end of the flue extension and apply a length of tape around the outer duct (Fig. 53).

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

Adaptor

Apply Lubricant for ease of assembly.

Ensure Extension is fully engaged into Boiler Adaptor

25mm

Extension

Cut End

Fig. 53

Tape

10.0 Installation

Fig. 54

Supplied by HeatingSpares247.com

10.0 Installation

10.7 Making The Electrical Connections

NOTE: Both the Live and Neutral connections are fused.

To connect an external control proceed as follows:-

1. Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel.

2. Completely undo the screws securing the facia panel and hinge it down (Fig. 55).

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

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

5. Refer to the instructions supplied with the control.

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

6. Remove the link between terminals 1 & 2. The switched output from the external control must be connected to terminal 1 (Fig. 57).

7. Ensure that the external control input cable(s) have sufficient slack to allow the control box to drop down. Tighten the cable clamp on the boiler chassis.

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

10.8 Preliminary Electrical Checks

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

2. These should be performed using a suitable meter, and include checks for Earth Continuity, Resistance to Earth, Short Circuit and Polarity.

Fig. 56

Fig. 57

Fig. 55

Terminal Block

Fuses

Cable Clamp

Facia Panel

Terminal Block Cover

Supplied by HeatingSpares247.com

Fused supply 3A 230V ~ 50Hz

230V

Earth (green/yellow)

Neutral (blue)

Live (brown)

Always fit fast

blow 2A fuse

11.0 Commissioning

Pump

Automatic Air

Vent

Pressure Gauge

Screw

bar

Fig. 59

Selector Switch

Central Heating

Temperature Control

Calibration

Control

Pump

Fig. 61

Fig. 60

Display

Heat Exchanger

Automatic Air Vent

Fig. 58

11.1 Commissioning the Boiler

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

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

3. Open the mains water supply to the boiler.

IMPORTANT: The heat exchanger air vent on top of the boiler (Fig. 58) MUST be opened before filling the primary system.

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

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

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

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

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

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

10. Test for gas tightness.

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

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

12. Having checked:

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

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

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

Proceed to put the boiler into operation as follows:

Supplied by HeatingSpares247.com

Reset

bar

11.0 Commissioning

Selector Switch

Display

Central Heating

Temperature Control

Calibration Control

Fig. 63

Fig. 64

Fig. 65

Fig. 66

Fig. 67

Central Heating

Temperature Control

Calibration Control

Fig. 62

x 2

11.2 Check the Operational (Working) Gas Inlet

Pressure

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

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

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

/4clockwise

twice and back fully anticlockwise (Fig. 62).

4. The display will now alternate between ‘SF’ and the current boiler temperature and both green LEDs will flash (Figs. 63 &

64).

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

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

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

Measure the Gas Rate

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

24 model 2.76 m

28 model 3.10 m

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

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

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.

Gas Valve

Gas Pressure

Test Point

Fig. 62a

Supplied by HeatingSpares247.com

Reset

bar

12.0 Completion

12.1 Completion

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.

Fig. 68

Facia Panel

Case Front Panel

Supplied by HeatingSpares247.com

13.0 Servicing

Case Front Panel

Fig. 69

Facia Panel Securing

Screws

Fig. 70

Inner Door

Panel

Fig. 71

Condensate

Trap

Sump

13 .1 Annual Servicing

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

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

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

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

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

• The operational gas inlet pressure as described in Section

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

• The combustion performance as described in ‘Check the

Combustion Performance’ (13.1.4 to 13.1.6 below).

3. Competence to carry out Checking Combustion

Performance

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

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

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

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

Check the Combustion Performance (CO/CO

ratio)

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

5. Remove the plug from the flue sampling point, insert the analyser probe and obtain the CO/CO

ratio. This must be

less than 0.004.

6. If the combustion reading (CO/CO

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

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

re-check

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

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

13.2 Annual Servicing - Inspection

1. Ensure that the boiler is cool.

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

boiler are isolated.

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

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

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

Supplied by HeatingSpares247.com

13.0 Servicing

13.2 Annual Servicing - Inspection (Cont)

6. Undo the nut on the gas pipe at the gas/air inlet (Fig. 72) and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector.

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. 73).

9. Undo the five retaining nuts and washers and remove the fan, gas/air inlet and burner assembly (Figs. 74).

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.

13. 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.

Gas Pipe

Injector

Fan Air Inlet Pipe

Gas/Air Inlet

Fan, Gas/Air Inlet &

Burner Assembly

Fig. 72

Fig. 73

Fig. 74

Supplied by HeatingSpares247.com

14.0 Changing Components

IMPORTANT: When changing components ensure that

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

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

14.1 Igniter (Fig. 75)

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.

14.2 Electrode Assembly (Fig. 76)

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

2. Undo the extended nuts 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.

Fig. 75

Igniter

Igniter Feed

Plug

Electrode

Leads

Fig. 76

Spark

Electrode

Leads

Sealing

Gasket

Supplied by HeatingSpares247.com

14.0 Changing Components

14.3 Fan

1. Undo the nut on the gas pipe at the gas/air inlet (Fig. 77) 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 (Fig. 78).

4. Undo the five retaining nuts and washers and remove the fan, gas/air inlet and burner assembly (Fig. 79).

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. 79).

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.

14.4 Injector (Fig. 77)

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

Fan

Gasket

Orifice Plate

Fig. 79

Fig. 77

Gas Pipe

Injector

Fan Air Inlet Pipe

Gas/Air Inlet

Gasket

Gas/Air Inlet

Fig. 78

Supplied by HeatingSpares247.com

14.0 Changing Components

14.5 Burner (Fig. 80)

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.

7. Reassemble in reverse order.

14.6 Insulation (Fig. 80)

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.

Fig. 80

Electrode Assembly

Burner

Insulation

Supplied by HeatingSpares247.com

14.0 Changing Components

14.7 Safety Thermostat (Fig. 81)

1. Pull the plug off the thermostat.

2. Remove the screws securing the thermostat to the mounting plate on the flow pipe.

3. Reassemble in reverse order, ensuring that the plug is pushed fully on.

14.8 Central Heating Temperature Sensor (NTC)

(Fig. 82)

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.

14.9 Water Pressure Sensor (Fig. 83)

1. Drain the boiler primary circuit.

2. Disconnect the two wires 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. The component is not polarised - either wire will fit each terminal.

14.10 DHW Temperature Sensor (NTC) (Fig. 83)

1. Turn off the mains cold water supply tap and draw off the residual domestic hot water.

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

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

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

Central Heating

Temperature Sensor

Safety Thermostat

Fig. 81

Fig. 82

Fig. 83

Water Pressure Sensor

Domestic Hot Water Temperature Sensor

Supplied by HeatingSpares247.com

14.0 Changing Components

14.11 Heat Exchanger Automatic Air Vent (Fig. 84)

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

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

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

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

14.12 Pump - Head Only (Fig. 85)

1. Drain the boiler primary circuit and remove the socket head screws securing the pump head to the body and draw the head away.

2. Undo the screw on the pump wiring cover and remove the cover. Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position.

3. A standard replacement Grundfos 15-60 head can now be fitted. Connect the pump wiring to the new head. The pump speed must be set to 3 (Fig. 86).

4. Reassemble in reverse order.

14.13 Pump - Complete (Fig. 87)

1. Drain the boiler primary circuit.

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

3. Undo the screw on the pump wiring cover and remove the cover. Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position.

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

5. Connect the wiring to the new pump. Examine the ‘O’ ring seals on the return pipe and manifold, replacing if necessary.

6. Fit the air vent to the pump body and reassemble in reverse order.

14.14 Automatic Air Vent (Fig. 87)

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

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

3. Reassemble in reverse order.

Pump Setting

Socket Headed

Screw

Pump Head

Pump Body

Automatic Air

Vent

Fig. 85

Fig. 87

Fig. 86

Pump Wiring

Cover

Pump Wiring

Cover

Heat Exchanger

Air Vent

Grommet

Fig. 84

Supplied by HeatingSpares247.com

14.0 Changing Components

14.15 Pressure Gauge (Figs. 88 & 89)

1. Drain the boiler primary circuit and undo the nut on the pressure gauge capillary.

2. Undo the screws securing the gauge retaining bracket.

3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining bracket.

4. Examine the sealing washer, replace if necessary.

5. Reassemble in reverse order.

14.17 Pressure Relief Valve (Fig. 90)

1. Drain the boiler primary circuit.

2. Disconnect the discharge pipe from the valve. Using a suitable hexagon key undo the grub screw sufficiently to release the valve.

3. Note the orientation of the valve, rotate it and withdraw it from the manifold.

4. Fit the new valve and ‘O’ ring seal and set to the previously noted orientation. Reassemble in reverse order.

Pressure Gauge

Capillary

Gauge Retaining

Bracket

Fig. 89

Fig. 88

‘O’ Ring Seal

Discharge

Pipe

Grub Screw

Pressure

Relief Valve

Fig. 90

Supplied by HeatingSpares247.com

14.0 Changing Components

14.18 P.C.B. (Figs. 91 & 92)

1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins.

2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots. Disengage the rear of the cover from the control box hinge pin.

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

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

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

14.19 Selector Switch (Figs. 91 & 92)

1. Note the setting of the selector switch knob and carefully pull it off the facia.

2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots. Disengage the rear of the cover from the control box hinge pin.

3. Note the position of the electrical connections and the orientation of the switch. Remove the electrical connections.

4. Remove the screws securing the switch to the facia panel.

5. Fit the new switch, ensuring that it is correctly positioned and reassemble in reverse order.

Control Box Cover

P.C.B.

Selector

Switch

Facia

Selector Switch Knob

Temperature Control Knobs

Fig. 91

Fig. 92

Drive Pins

Supplied by HeatingSpares247.com

14.0 Changing Components

14.20 Gas Valve (Fig. 93)

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

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

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

6. Reassemble in reverse order., ensuring that all seals are in place and the injector is fitted.

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. 93a). If the boiler will not light, or the correct CO

cannot be achieved

contact the ‘heateam’ technical helpline.

14.21 Expansion Vessel (Fig. 94)

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.

Gas Valve

Gas Feed

Elbow

Fig. 93

Earth Lead

Expansion Vessel

Boiler Chassis

Lock Nut

Spring

Washer

Fig. 94

Retaining Bracket

Sensing Pipe

Venturi Inlet

Pipe

Power Lead

Fig. 93a

Throttle

Adjustment Screw

Supplied by HeatingSpares247.com

Selector Switch

Display

Central Heating

Temperature Control

Domestic Hot Water Temperature Control

Fig. 96

Fig. 97

Fig. 98

Fig. 99 Fig. 100

Central Heating

Temperature Control

Calibration Control

Fig. 95

x 2

Fig. 101

Flue Adaptor Test

Point

Plug

Analyser Probe

Throttle

Adjustment Screw

(cover removed)

Offset

Adjustment Screw

(cap fitted)

Gas Valve

Fig. 102

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.

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

Reduce CO

at min. rate

Increase CO

at min. rate

Reduce CO

at max. rate

Increase CO

at max. rate

15.0 Setting the Gas Valve

15.1 Setting the Gas Valve (CO

check)

IMPORTANT: The CO

must 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

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

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

3. Turn both control knobs fully anticlockwise, then quickly turn the right hand knob

/4clockwise twice and back fully

anticlockwise (Fig. 95).

4. The display will now alternate between ‘SF’ and the current boiler temperature and both green LEDs will flash (Figs. 96 & 97).

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

6. The display will show ‘00’, indicating maximum rate, then revert to ‘P ‘ alternating with the current boiler temperature (Figs. 98, 99 & 100).

7. Remove the plug from the flue sampling test point. Insert the analyser probe and allow sufficient time for the reading to settle (Fig. 101).

The CO

should be 9.0% + 0.0 - 0.4

8. It is possible to alter the CO

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. 102). Turning clockwise will reduce the CO

. Anticlockwise will

increase th e CO

9. The CO

must then be checked at 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.

The CO

should be 8.4% + 0.0 - 0.4

10. With the boiler on minimum, the Offset Adjustment Screw must be altered, using a suitable hexagon key, after removing the cap (Fig. 102). Turning anti-clockwise will reduce the CO

. Clockwise will increase th e CO2.

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

12. Check the Combustion Performance (CO/CO

ratio).

This must be less than 0.004.

Supplied by HeatingSpares247.com

Reset

bar

16.0 Electrical

Water Pressure

16.1 Illustrated Wiring Diagram

Supplied by HeatingSpares247.com

Switch

Return Heating Temp Sensor

Central Heating NTC Sensor

Overheat Stat

54321

X401

54321

910 8 7 6

X400

9876

g/y

Fan

Link

Control PCB

X501

Ignition Electrode

Pump

Gas Valve

556789

Spark Generator

g/y

X2 X3

1212 3344

Mains Input

br bk b w

- brown

- black

- blue

- white

- green

- green / yellow

g/y

- red

- greygr

17.0 Short Parts List

Short Parts List

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

A Fan 5121447

B Electrode Assembly 5130293

C Gas Valve 5122149

D Burner 5130292

E Water Pressure Switch 5114748

F Pump 248042

G NTC Sensor 5114725

H Overheat Thermostat 5114729

J NTC Sensor 5130291

K Pressure Gauge 248090

L PCB 24 5131262

PCB 28 5131263

Supplied by HeatingSpares247.com

18.0 Fault Finding

NOTE: When instructed to turn the

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

18.1 Initial Fault Finding Checks

1. Check that gas, water and electrical supplies are available at the boiler.

2. Electrical supply = 230V ~ 50 Hz.

3. CH water system pressurised to 0.5 bar minimum when the boiler is cold.

4. The preferred minimum gas pressure is 20 mbar.

5. Carry out electrical system checks, i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable meter.

NOTE: These checks must be repeated after any servicing or fault finding.

6. Ensure all external controls are calling for heat and check all external and internal fuses. Before any servicing or replacement of parts, ensure the gas and electrical supplies are isolated.

18.2 Error Codes

1. If a fault occurs on the boiler an error code may be shown by the facia display.

2. The codes are either two or three digit, preceded by the letter 'E'. For example, code E133 will be displayed by 'E1' alternating with '33'. E50 is shown as 'E' then '50'

E20, E28 & E50 indicate faulty or incorrect components.

E110 shows overheat of the primary water.

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.

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 Power Supply while in fault mode Interruption Of Gas Supply or Flame Failure Fan or Fan Wiring Fault

E20 E28 E50 E110 E119 E125 E131 E133 E160

Table Of Error Codes

Supplied by HeatingSpares247.com

18.0 Fault Finding

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

Turn selector switch to

The display illuminates

Error 20, 28 or 50 flashing

Error 119 flashing

Burner lights

Error 110 flashing Error 133 flashing

Turn Central Heating

thermostat to Maximum.

Pump runs

Fan runs

Spark at ignition electrodes for

up to 5 seconds and for 3

attempts

3-way valve is open to Central

Heating circuit

Go to section ‘A’

Go to section ‘E’

Ensure all controls (and

integral clock if fitted) are

calling for heat

Go to section ‘J’

Go to section ‘B’

Error 160 flashing

Go to section ‘D’

Error 133 flashing

Burner does not stay alights

after 5 seconds

Error 133 flashing Go to section ‘H’

Operation sequence

successful

If the error 110 is still flashing.

Go to section ‘I’

Fan runs at correct speed

YES

YES YES

YES

YES YES

YES

Burner output modulates to

maintain the temperature set

Burner goes out

Go to section ‘C’

Ensure controls are set to

demand and verify the

contacts are closed

Error 160 flashing

Go to section ‘K’

YES

Go to section ‘G’

Turn the selector switch to

reset

Go to section ‘F’

YES

Check the Central Heating

NTC sensor

Go to section ‘E’

Fan stops after 10 seconds

Pump continues to run for 3

minutes

(room thermostat open)

YES

Turn the selector switch to

reset position for 5 seconds

Error 125 flashing

Ensure that primary

circulation is OK & that

there is no blockage

YES

Supplied by HeatingSpares247.com

18.0 Fault Finding

Fault Finding Solutions Sections

Is there 230V at:

Main terminals L and N Check electrical supply

Main terminal fuse Replace fuse

Replace PCB

Display illuminated

PCB - X1 connector terminals 1,2

Check wiring

Pump Replace pump

YES

PCB - X3 connector terminals 3 & 4 Replace PCB

Change pump supply cable

YES

CH system pressure less than 0.5 bar Re-pressurise system

YES

Check the tap of the automatic air vent is opened

Open the automatic air vent

YES

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

Fan jammed or faulty winding

Replace PCB

Replace fan

YES

If pump jammed, release

Replace water pressure switch

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

YES

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

E28 - Incorrect PCB fitted

Replace sensor or PCB (E28)

Supplied by HeatingSpares247.com

18.0 Fault Finding

Gas at burner

Ensure gas is on and purged

Replace PCB

Replace gas valve

PCB - X3 connector is 230V AC across

terminals 1 & 2

YES

Replace PCB

Check and correct if necessary

1. Ignition electrode and lead

2. Electrode connection

3. Spark gap and position

voltage at PCB - X2 connector is 110V AC across terminals 2 & 5 (Note: from multimeter connect ‘common’ to 2 & ‘volts’ to 5) Check wiring

YES

Replace igniter

YES

Check and correct the connection of the

tube between the venturi and gas valve

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 μ A

Replace PCB

YES

Replace flame sensing electrode

Check the gas supply pressure:

For Natural Gas MINIMUM 17 mbar

Replace safety thermostat

YES

Overheat thermostat operated or

faulty, i.e. continuity across

thermostat terminals

Allow to cool. Continuity

across thermostat terminals

more than 1.5 ohm

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18.0 Fault Finding

Is there 230V at: PCB - X3 connector terminals 5 & 6 central heating mode

Replace PCB

Change pump supply cable

YES

Fan connections correct at fan. PCB - X401 connector terminals 5,6,7 & 8

YES

Replace fan

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

Replace sensor

YES If pump is running the heat exchanger could be obstructed

Replace heat exchanger

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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.

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

CONDENSING BOILERS ONLY

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

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

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Service Record

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

Service Provider

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

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

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Operative ID No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Service 1 Service 2

Service 3 Service 4

Service 5 Service 6

Service 7 Service 8

Service 9 Service 10

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Comp No5119528 - Iss 5 - 6 /11

All descriptions and illustrations provided in this leaflet have been

carefully prepared but we reserve the right to make changes and

improvements in our products which may affect the accuracy of the

information contained in this leaflet. All goods are sold subject to our

standard Conditions of Sale which are available on request.

MAIN

A Trading Division of Baxi Heating UK Ltd (3879156)

Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 0844 871 1570 Technical Enquiries 0844 871 1555 Website www.mainheating.co.uk e&oe

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Main System 28 Eco, System 24 Eco Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual