- Home
- Domestic appliances
- Large home appliances
- Water heaters & boilers
- Potterton
- Promax 18 SL
- User manual
advertisement
Installation & Service Instructions
You can rely on
Promax SL
Range
Condensing
Central Heating
Boiler
These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2014
Natural Gas
Potterton Promax 12 SL
G.C.N
o 41 591 79
Potterton Promax 15 SL
G.C.N
o 41 591 87
Potterton Promax 18 SL
G.C.N
o 41 591 80
Potterton Promax 24 SL
G.C.N
o 41 591 88
Potterton Promax 30 SL
G.C.N
o 41 591 89
The Benchmark Scheme
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the
Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.uk for more information.
© Baxi Heating UK Ltd 2014 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.
2
© Baxi Heating UK Ltd 2014
0086
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.
ISO 9001
FM 00866
Installer Notification Guidelines
Competent Person's
Self Certification Scheme
Choose Building
Regulations Notification
Route
Install and Commission this appliance to manufacturer's instructions
Complete the
Benchmark Checklist
If you notify via the ‘Gas Safe
Register’, the register will issue the Building Regulations certificate on members’ behalf
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
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
Complete the
Benchmark Checklist
LABC will record the data and will issue a certificate of compliance
© Baxi Heating UK Ltd 2014
3
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”.
NOTE: 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
Legislation
This company declares that no substances harmful to health are contained in the appliance or used during appliance manufacture.
The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force, and only used in a suitably ventilated location.
In GB, the installation must be carried out by a Gas Safe
Registered Installer. It must be carried out in accordance with the relevant requirements of the:
• Gas Safety (Installation & Use) Regulations.
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
• The Water Fittings Regulations or Water Byelaws in
Scotland.
• The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a competent
Person and installed in accordance with the current edition of I.S. 813 ‘Domestic Gas Installations’, the current Building
Regulations and reference should be made to the current
ETCI rules for electrical installation.
All 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 o 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.
Codes of Practice, most recent version should be used
In GB the following Codes of Practice apply:
Standard Scope
BS 6891
BS 5546
Gas Installation.
Installation of hot water supplies for domestic
BS EN 12828
BS EN 12831
BS EN 14336 purposes.
Heating systems in buildings.
Heating systems in buildings - calculations of load
Installation & commissioning of water based
BS 6798
BS 5440 Part 1
BS 5440 Part 2
BS 7074
BS 7593 heating systems.
Installation of gas fired hot water boilers.
Flues.
Ventilation.
Expansion vessels and ancillary equipment for sealed water systems.
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 BS standards give valuable additional information;
BS 5546 Installation of hot water supplies for domestic purposes.
BS EN 12828
BS EN 12831
BS EN 14336
Heating systems in buildings.
Heating systems in buildings - calculations of load
Installation & commissioning of water based heating systems.
BS 7074
BS 7593
Expansion vessels and ancillary equipment for sealed water systems.
Treatment of water in domestic hot water central heating systems.
4
© Baxi Heating UK Ltd 2014
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 section 8.3 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 !!
© Baxi Heating UK Ltd 2014
5
6
© Baxi Heating UK Ltd 2014
Contents
Section
1.0
Introduction
2.0
General Layout
3.0
Appliance Operation
4.0
Technical Data
5.0
Dimensions and Fixings
6.0
System Details
7.0
Site Requirements
8.0
Flue Options
9.0
Plume Displacement
10.0
Installation
11.0
Electrical
12.0
Commissioning the Boiler
13.0
Fitting the Outer Case
14.0
Servicing the Boiler
15.0
Changing Components
16.0
Short Parts List
17.0
Fault Finding
Benchmark Checklist
43
46
39
42
31
37
22
27
53
54
62
12
16
10
11
Page
7
8
9
Fig. 1
Lower Door Panel
Position of Label
Air Box Door
Fig. 2
Data Badge
© Baxi Heating UK Ltd 2014
1.0 Introduction
1.1
Description
1. The Potterton Promax SL range are gas fired room sealed fan assisted condensing central heating boilers.
2. The maximum output of the Potterton Promax 12 SL is
40,330 Btu/hr,15 SL model is 52,000 Btu/hr, 18 SL model is
60,770 Btu/hr and 24 SL model is 75,000 Btu/hr. The maximum output of the 30 SL model is preset at 75,000 Btu/hr but can be set to 100,000 Btu/hr (see section 10.8). All boilers automatically adjust their outputs according to the system load.
3. It is designed for use on Natural Gas (G20).
4. The boiler is suitable for fully pumped open vented central heating and domestic hot water systems and sealed systems.
5. A label giving details of the model, serial number and Gas
Council number is situated on the rear of the lower door panel
(Fig. 1).
6. The boiler data badge is positioned on the air box door
(Fig. 2).
7. The boiler is intended to be installed in residential / domestic environments on a governed meter supply only.
8. The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit, part no
236921.
1.2
Important Information
Man-made mineral fibre
• Some component parts of this appliance (insulation pads, gaskets and rope seals) are manufactured from man-made mineral fibre.
• Prolonged or excessive exposure to this material may result in some irritation to the eyes, skin or respiratory tract.
• It is advisable to wear gloves when handling these items.
• Irritant dust will only be released from the items if they are broken up or subjected to severe abrasion. In these instances a suitable dust mask and goggles should be worn.
• Always thoroughly wash hands after installation, servicing or changing components.
• When disposing of any items manufactured from man-made mineral fibre care must be exercised.
• If any irritation of the eyes or severe irritation of the skin is experienced seek medical attention.
1.3
Contents of Pack
The pack contains:-
• Boiler
• Wall Plate
• Template & ‘Quick Fit’ Guide
• Literature Pack
• Fittings Pack
7
4
5
6
3
2
16
Fig. 5
15 14
1
2.0 General Layout
2.1
Layout (Figs. 3,4,5 & 6)
13.
14.
15.
16.
9.
10.
11.
12.
7.
8.
5.
6.
3.
4.
1.
2.
Wall Plate
Flue Elbow
Heat Exchanger
Burner
Air Box
Fan Protection Thermostat
Fan Assembly
Condensate Trap
PCB Housing Assembly
Gas Tap
Gas / Air Ratio Valve
Flow Pipe Connection
Return Pipe Connection
Flow Temperature Safety Thermostat - Black
Flow Temperature Thermistor - Red
Flow Switch (dry fire protection)
13
12
Fig. 3
7
9
8
Fig. 4
8
© Baxi Heating UK Ltd 2014
Fig. 6
10
11
Mains On.
Flow temperature less than set point ?
YES
10 second
Pump On.
NO
NO
Flow switch made ?
YES
5 second
Fan Pre-Purge.
YES Ignition done and less than 5 attempts made ?
5 second
Ignition Period.
Flame Detected ?
YES
Burner On.
All TRVs shut or Flow temperature greater than set point ?
YES
5 second
Fan Post Purge.
Ignition done and
5 attempts made ?
YES
Ignition
Lockout.
YES
All TRVs shut down ?
NO
1 minute
Pump Overrun.
3 minute
Anti-cycle.
© Baxi Heating UK Ltd 2014
3.0 Appliance Operation
3.1
1. Switched Live On: When the switched live switches on if the flow temperature is less than the set point then pump overrun occurs. When the switched live switches on if the flow temperature is greater than the set point then pump overrun occurs.
2. Pump On: The pump is on while the fan, spark generator and gas valve are off. After 10 seconds if the flow switch has made then fan pre-purge occurs. After
10 seconds if the flow switch has not made then anticycle occurs.
3. Fan Pre-Purge: The pump and fan are on while the spark generator and gas valve are off. After 5 seconds ignition occurs.
4. Ignition: The pump, fan, spark generator and gas valve are on. If a flame is detected then burner on occurs. If a flame is not detected within 5 seconds and less than 5 ignition attempts have been made then fan purge occurs. If a flame is not detected within 5 seconds and 5 ignition attempts have been made then ignition lockout occurs.
5. Burner On: The pump, fan and gas valve are on while the spark generator is off. Flow temperature is controlled by varying the fan speed (and thereby the gas rate) to achieve optimum operation. If the flow temperature is greater than the set point or the TRVs all shut down then fan post purge occurs.
6. Fan Post Purge: The pump and fan are on while the spark generator and gas valve are off. After 5 seconds if the TRVs are not shut down then pump overrun occurs. After 5 seconds if the TRVs are shut down then anti-cycle occurs.
7. Pump Overrun: The pump is on while the fan, spark generator and gas valve are off. After 1 minute anticycle occurs.
8. Anti-cycle: The pump, fan, spark generator and gas valve are off. After 3 minutes if the flow temperature is less than the set point then pump on occurs. After 3 minutes if the flow temperature is greater than the set point then pump overrun occurs.
9. Ignition Lockout: The pump, fan, spark generator and gas valve are off. The boiler can only be reset by manually using the reset button.
9
4.0 Technical Data
Appliance Type C
13
C
33
C
53
Appliance Category CAT I
2H
Heat Input (Q)(Gross)
12 model kW
Max
13.34
Btu/hr 45,518
15 model
18 model kW 16.88
Btu/hr 57,600 kW 20.18
Btu/hr 68,850
24 model
30 model
(see note) kW 24.50
Btu/hr 83,600
10.2
34,840 kW 33.76
10.2
Btu/hr 115,200 34,840
Min
10.2
34,840
10.2
34,840
10.2
34,840
Heat Output (P)
(Non Condensing 70° C Mean Water Temp)
Max Min
12 model
15 model kW 11.82
Btu/hr 40,330 kW 15.24
Btu/hr 52,000
9.14
31,180
9.14
31,180
18 model
24 model
30 model kW 17.81
Btu/hr 60,770 kW 22.00
Btu/hr 75,000 kW 30.18
Btu/hr 102,980
9.14
31,180
9.14
31,180
9.14
31,180
Heat Output (P)
(Condensing 40° C Mean Water Temp)
Max Min
12 model
15 model kW 12.81
Btu/hr 43,400 kW 16.49
Btu/hr 56,260
10.1
34,520
18 model
24 model
30 model kW 19.27
Btu/hr 64,898 kW 23.8
Btu/hr 81,200 kW 32.61
Btu/hr 113,280
10.1
34,520
10.1
34,520
NOTE: The maximum output of the 30 model is factory set at 22.0kW (75,000
Btu/hr). This can be altered to 30.18kW
(102,980 Btu/hr) - see section 10 .8.
SEDBUK Declaration
For 12 model - The efficiency is 90.5%
For 15 model - The efficiency is 91.3%
For 18 model - The efficiency is 90.4%
For 24 model - The efficiency is 90.9%
For 30 model - The efficiency is 90.9%
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.
10
© Baxi Heating UK Ltd 2014
Max Gas Rate (2H - G20 - 20mbar)
(After 10 Mins)
(12) (15) (18)
Btu/hr 40,950 52,000 61,400 m ft 3
3 /hr
/hr
1.34
47.3
1.64
52.1
1.94
68.5
(24) (30)
75,000 102,980
2.31
83.3
2.95
104.2
Injector (Natural Gas)
6.5mm Diameter
Nox Class 5
Horizontal
Flue Terminal
Dimensions
Connections
Gas Supply
Central Heating Flow
Central Heating Return
Condensate Drain
Diameter 110mm
Projection 150mm
1 /
2 in BSPT
22mm
22mm
1 in BSP
Outercase Dimensions
Overall Height
Inc Flue Elbow
Casing Height
Casing Width
Casing Depth
-
-
-
750mm
600mm
390mm
280mm
Clearances
(For unventilated compartments see Section 7.2)
Both Sides
Above Casing
Below Casing
Front (For Servicing)
Front (In Operation)
5mm Min
200mm Min
50mm Min
500mm Min
5mm Min
Weights
Packaged Boiler Carton
Packaged Flue Kit
Installation Lift Weight
CO/CO 2 Ratio
CO 2 Level kg
36.2
3.6
26.0
Up to a maximum of 0.004
9% ± 1%
NOTE: All data in this section are nominal values and subject to normal production tolerances
Electrical Supply 230V~ 50Hz
(Appliance must be connected to an earthed supply)
Power Consumption 80W
External Fuse Rating 3A
Internal Fuse Rating (BS 4265)
Fuse
Water Content litres pints
2.6
4.6
Static Head max min
Low Head
Min
Max
3.15 AT (PCB)
Electrical Protection
18.1 mbar
22.5 mbar
IPX2
30 metres (100 ft)
1 metre (3.25 ft)
0.2m (8 in) min
System Detail fully pumped open vented & sealed systems
Gas Connection
G 1 /
2
” B.S.P. Thread
Controls boiler thermostat, safety thermostat, flow switch, electronic flame sensing, temperature protection thermostat & condensate blockage sensor
Inlet Pressure at Gas Valve (Natural Gas)
(see Section 12.1)
Flow Temperature (adjustable)
55° C to 78° C (± 5° C)
Recommended System
Temperature Drop
Condensing 20°C 36°F
Hydraulic Resistance Chart
220
200
180
160
140
120
100
80
60
40
20
0 10 20 30
Water Flow Rate (litres/min)
40
91
83
75
66
58
50
42
33
25
17
8
At Least 1.5°
D
A
E
B
360° Orientation
C
Tube Ø 110mm
5.0 Dimensions and Fixings
DIMENSIONS
A 600mm
B 280mm
C 390mm
D 150mm Ø Min.
E 162.5mm
F 96mm
The 1.5° fall provided by the elbow is to allow condensate to run back to the boiler, for disposal through the condensate discharge pipe.
Fig. 7
F
Y
X
At Least 1.5°
SIDE FLUE (left and right)
For every 1m of horizontal flue length, the clearance above the top of the flue elbow should be 27.5mm
to incorporate the 1.5° fall in the flue from the terminal to the elbow.
Flue length (Y) up to 1m
1m - 2m
2m - 3m
Clearance (X)
27.5mm
55mm
82.5mm
Fig. 8
© Baxi Heating UK Ltd 2014
11
12
© Baxi Heating UK Ltd 2014
6.0 System Details
6.1
Water Circulating Systems
1. The appliance is suitable for use with open vent fully pumped systems and sealed systems .
The following conditions should be observed on all systems:
• The static head must not exceed 30m (100ft) of water.
• The boiler must not be used with a direct cylinder.
• Drain cocks should be fitted to all system low points.
• All gas and water pipes and electrical wiring must be installed in a way which would not restrict the servicing of the boiler.
• Position isolating valves as close to circulating pump as possible.
• It is recommended that the return pipe is fitted with an automatic air vent as close to the boiler as is practical.
6.2
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.
Fig. 9
Fig. 10
Boiler
Copper
0.5m
Copper
1m
Copper
0.5m
Flow
Return
500mm
45°
22mm
Open Vent
1000mm
Min
150mm
Max
15mm
Cold
Feed
400mm
Min Head
Boiler
Pump
Flow
Return
Typical Low Head Installation
Boiler
Automatic Air
Vent
1000mm
Min
500mm
45°
22mm
Open Vent
15mm
Cold
Feed
150mm
Max
400mm
Min Head
Pump
Return
6.0 System Details
6.3
Pipework
1. The sizes of flow and return pipes from the boiler should be determined by normal methods, according to the requirements of the system. The connections on the boiler are 22mm.
2. A 20 °C (36°F) drop in temperature across the system is recommended for condensing boilers. Existing radiators may be oversized and so allow this, but where radiator sizing is marginal it may be advisable to retain a system temperature drop of 11°C (20°F).
NOTE: On 30 models 28mm pipe should be used to connect to the boiler flow and return.
3. In systems using non-metallic pipework it is necessary to use copper pipe for the boiler Flow and Return. The copper must extend at least 1 metre from the boiler and include any branches (Fig. 9).
Flow
6.4
Low Head Installation
1. Using a close couple arrangement the minimum head is as shown in the diagrams (Figs. 10 & 11) subject to the following conditions: a) The pump being adjusted to give a 20°C drop across the boiler.
b) The pump must be fitted on the flow.
c) The pump must be fitted in accordance with the pump manufacturer's instructions.
d) The open vent pipe must be taken up from a tee in a horizontal section of the flow pipe.
An alternative Low Head Installation (Fig. 12)
2. For heads below 400mm then a combined vent and feed pipe may be connected. This must be a minimum of 22mm diameter. It is recommended that an air separator is fitted when using a combined feed and vent pipe.
Fig. 11
6.5
Pump
1. Providing that the cold feed and open vent pipe are positioned correctly (e.g. the system is not prone to pumping over, air entrainment etc.) the pump may be fitted on the primary return pipe.
Fig. 12
If Conditions Require,
This System Possible
Boiler
200mm
Min
22mm
Feed & Vent
Pipe
Air
Separator
Pump
Return
Alternative Low Head Installation
Flow
© Baxi Heating UK Ltd 2014
13
230V
50Hz
L N E b g/y
Room
Stat w
Cylinder
Stat
1
C 2 gr o
Y Plan
Diverter
Valve
L
Boiler
E N P/F
Key to colours b Blue br Brown w White o Orange gr Grey g/y Green/Yellow
6.0 System Details
6.6
System Controls
This boiler does not require a bypass.
This boiler does not require a permanent live.
The pump only needs wiring directly to the boiler for fully TRV’d systems.
Timer
L
N
CH on
HW on
HW off
N E L
Pump
Y Plan, Room Thermostat System, CH Interlocked By Room Thermostat
At least the Radiator(s) near the Room Thermostat not TRV’d
Pump run from Switched Live
By-pass permitted but not required for Part L1 compliance
1. To comply with Part L1 of the Building Regulations the heating system into which the boiler is installed should include the following: a) zone controls b) timing controls c) boiler control interlocks
230V
50Hz
L N E
2. Such a system needs to be fully pumped and must provide independent temperature and time control to both the heating and hot water circuits and have a boiler interlock.
gr b gr b
Motor g/y br
S Plan
Valve
Room
Stat
Cylinder
Stat o
Motor br g/y
S Plan
Valve o
L
Boiler
E N P/F
3. The boiler should be controlled so that it operates on demand only. Where it is proposed to effect control by thermostatic radiator valves, a room thermostat (or other device such as a flow switch - a flow switch is integral to this boiler) should also be provided to switch off the boiler when there is no demand for heating or hot water.
Timer
L
N
CH on
HW on
N E L
Pump
S Plan, Room Thermostat System, CH Interlocked By Room Thermostat
At least the Radiator(s) near the Room Thermostat not TRV’d
Pump run from Switched Live
By-pass permitted but not required for Part L1 compliance
4. The interlock for the CH circuit can be provided by either a Room Thermostat or a fully TRV’d system with the pump wired back to the boiler without a bypass.
Connection diagrams for both options for Y and S plan systems are shown.
230V
50Hz
L N E
230V
50Hz
L N E g/y b w
Cylinder
Stat
1 gr o
Y Plan
Diverter
Valve
C 2
L
Boiler
E N P/F gr b gr
Motor Motor b g/y br
S Plan
Valve
Cylinder
Stat o br g/y
S Plan
Valve o
L
Boiler
E N P/F
Timer
L
N
CH on
HW on
HW off
N E L
Pump
Y Plan, Fully TRV’d System, CH Interlocked By Boiler Flow Switch
Room Thermostat should not be fitted
Pump must be run from Boiler P/F connection for Part L1 compliance
By-pass not permitted (must be valved off) for Part L1 compliance
Timer
L
N
CH on
HW on
N E L
Pump
S Plan, Fully TRV’d System, CH Interlocked By Boiler Flow Switch
Room Thermostat should not be fitted
Pump must be run from Boiler P/F connection for Part L1 compliance
By-pass not permitted (must be valved off) for Part L1 compliance
14
© Baxi Heating UK Ltd 2014
Air
Vent
3 Litre
Top Up Bottle
(if required)
Safety
Valve
Pressure
Gauge
Filling
Point
Pump
Fig. 13
Table. 1
Boiler
Expansion
Vessel
System Drains at
Low Point
Max Boiler Flow
Temp = 82° C
Radiator
Circuit
Method of determining minimum valve of expansion vessel volume for sealed systems using Potterton Boilers
Vessel Charge
Pressure (Bar)
0.5
1.0
1.5
Initial System
Pressure (Bar)
0.5
1.0
1.5
2.0
1.0
1.5
2.0
1.5
2.0
Multiply Total
Water Content Of
System By (Litres)
0.067
0.112
0.207
0.441
0.087
0.152
0.330
0.125
0.265
Example :-
Then :-
System Volume = 75 litres
Vessel Charge Pressure = 1.0 bar
Initial System Pressure = 1.5 bar
75 x 0.152 = 11.4 litres
Expansion Vessel Volume
NOTE
Where a vessel of the calculated size is not obtainable then the next available larger size should be used.
Stop
Valve
Double
Check
Valve
Stop
Valve
6.0 System Details
6.7
Sealed Systems
(Fig. 13)
1. SAFETY VALVE - A safety valve complying with the requirements of BS 6750 Part 1 must be fitted close to the boiler on the flow pipe by means of a horizontal or vertically upward connection with no intervening valve or restrictions and should be positioned to facilitate testing. The valve should be pre-set and non-adjustable to operate at a pressure of 3 bar (45 Ibf/in 2 ). It must be arranged to discharge any water or steam through a pipe to a safe outlet position.
2. PRESSURE GAUGE - A pressure gauge of minimum range 0-4 bar (0-60 Ibf/in 2 ) with a fill pressure indicator must be fitted to the system, preferably at the same point as the expansion vessel in an easily visible position.
3. EXPANSION VESSEL - An expansion vessel complying with the requirements of BS 4814 must be fitted to the system by means of a connection close to the inlet side of the circulating pump in accordance with the manufacturers instructions, the connecting pipe being unrestricted and not less than 15mm ( 1 /
2 in) nominal size.
The volume of the vessel should be suitable for the system water content and the nitrogen or air charge pressure should not be less than the system static head
(See Table. 1).
Further details of sealed system design can be obtained from BS 5449 and the British Gas publication entitled
'Specifications for Domestic Wet Central Heating
Systems'.
4. FILLING POINT - 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. The sealed primary circuits may be filled or replenished by means of a temporary connection between the primary 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. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment.
Your attention is drawn to, for GB: Guidance G24.2 and recommendation R24.2 of the Water Regulations Guide.
for IE: the current edition of I.S. 813 “Domestic Gas
Installations”.
5. MAKE UP SYSTEM - A method of replacing water lost from the system should be provided either by means of a make up vessel of not more than 3 litres (5 pints) capacity, mounted above the highest point of the system, or by re-pressurisation of the system.
6. VENTING - A method of venting the system during filling and commissioning must be provided by fitting automatic air vents or by venting manually.
7. HOT WATER STORAGE - The hot water storage vessel must be of the indirect coil type. All components used in the system must be suitable for operation at
110°C (230°F) and at the pressure allowed by the safety valve.
Fig. 14
© Baxi Heating UK Ltd 2014
Cold
Mains
Inlet
Temporary
Hose
CH
Return
15
Zone 1
Zone 2
Window
Recess
Zone 2
Zone 0
0.6 m
Window
Recess
Zone 2
Fig. A
In GB Only
Window Recess
Zone 2
Ceiling
Outside Zones
Zone 1 Zone 2
2.25 m
Zone 0
Fig. B
0.6 m
In GB Only
7.0 Site Requirements
7.1
Location
NOTE: Due to the high efficiency 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 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 7.2).
2. If the boiler is sited in an unheated enclosure then it is recommended to incorporate an appropriate device for frost protection in the system controls.
3. If the boiler is fitted in a room containing a bath or shower it MUST NOT BE fitted in zone 0, 1 or 2, ONLY within the shaded area (Figs. A & B shows zone dimensions for a bathtub. For other examples refer to the Current I.E.E. Wiring Regulations) reference must be made to the relevant requirements.
In GB this is the current I.E.E. Wiring Regulations and
Building Regulations.
In IE reference should be made to the current edition of
I.S. 813 “Domestic Gas Installations” and the current
ETCI rules.
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
Ventilation of Compartments
1. Where the boiler is installed in a cupboard or compartment, no air vents are required for cooling purposes providing that the minimum dimensions below are maintained.
Sides
Top
Bottom
Front
15mm
200mm
50mm
30mm
2. If the boiler is installed in a smaller cupboard or compartment it must be ventilated according to
BS 5440 Part 2 and the minimum clearances given in section 4.0 “Technical Data” maintained.
3. Any compartment should be large enough to house the boiler only.
NOTE: The ventilation label on the front of the outer case MUST NOT BE REMOVED when the appliance is installed in a compartment or cupboard.
16
© Baxi Heating UK Ltd 2014
Fig. 15
5mm Min
500mm
For Servicing
Purposes
390mm 5mm Min
200mm
600mm
7.0 Site Requirements
7.3
Clearances (Figs. 15 &16)
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.
3. For unventilated compartments see Section 7.2.
50mm
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 1 /
2 in BSPF.
3. Ensure that the pipework from the meter to the appliance is of adequate size to ensure correct operation.
Do not use pipes of a smaller diameter than the boiler gas connection.
7.5
Electrical Supply
At Least 1.5°
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 ~ 50Hz fused at 3A.
NOTE: “The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance”.
Note! There is no method of isolating the boiler, at the user interface.
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.
WARNING: The PCB Control and Fan
Assembly are 325 Vdc. Isolate at supply before access.
Fig. 16
5mm
In Operation
280mm
© Baxi Heating UK Ltd 2014
17
Examples are shown of the following methods of termination:i) to an internal soil & vent pipe ii) via an internal discharge branch (e.g. sink waste) downstream of the trap iii) to a drain or gully iv) to a purpose made soakaway v) pumped into an internal discharge branch (e.g. sink waste) downstream of the trap vi) pumped into an external soil & vent pipe vii) to a drain or gully with extended external run & trace heating
It is strongly recommended to discharge internally into the household drainage system. If connecting to a rain water drain, that drain MUST discharge into a foul drain.
Sink
Boiler
21.5mm
32mm Insulation i) Termination to an internal soil and vent pipe
50mm per metre of pipe run
2.5° Minimum fall
450mm min* ii) External termination via internal discharge branch e.g sink waste - downstream*
50mm per metre of pipe run
2.5° Minimum fall
*450mm is applicable to properties up to 3 storeys.
For multi-storey building installations consult BS 6798.
Pipe must terminate above water level but below surrounding surface. Cut end at 45°
7.0 Site Requirements
7.6
Condensate Drain
FAILURE TO INSTALL THE CONDENSATE
DISCHARGE PIPEWORK CORRECTLY WILL AFFECT
THE RELIABLE OPERATION OF THE BOILER.
CAREFUL CONSIDERATION MUST BE GIVEN TO THE
POSSIBILITY OF THE PIPEWORK BEING SUBJECT TO
FREEZING CONDITIONS AND APPROPRIATE
MEASURES TAKEN TO PREVENT BLOCKAGE.
CORRECT INSTALLATION IN ACCORDANCE WITH
THIS SECTION WILL CONSIDERABLY MINIMISE THE
LIKELIHOOD OF BLOCKAGE AND SUBSEQUENT
BOILER LOCK-OUT.
A CONDENSATE DISCHARGE PUMP AND PIPE ‘TRACE
HEATING’ ARE AVAILABLE AS ACCESSORIES - see paragraphs 7.7.12 to 7.715 for further details.
The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST
2.5° (50mm per metre) along the entire run EXCEPT when employing a suitable condensate pump in basement and cellar or similar applications.
The boiler condensate trap incorporates a seal of 75mm, therefore it is unnecessary to install an air break and trap in the discharge pipework.
1. The condensate outlet will accept 21.5mm ( 3 /
4 in) plastic overflow pipe. It is strongly recommended that this discharges internally into the household drainage system.
Where this is not possible, discharge into an outside drain is permissible providing every possible precaution is taken to prevent freezing.
2. Ensure the discharge of condensate complies with any national or local regulations in force. BS 6798 & Part H1 of the Building Regulations give further detailed guidance.
3. The discharge pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP.
4. Metal pipework is NOT suitable for use in condensate discharge systems.
5. The pipe should be a minimum of 21.5mm diameter and must be supported using suitably spaced clips of the correct design to prevent sagging.
6. It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres.
7. Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe.
8. External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external use.
9. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run and sized and insulated accordingly.
10. In all cases discharge pipe must be installed to aid disposal of the condensate. To reduce the risk of condensate being trapped, as few bends and fittings as possible should be used and any burrs on cut pipe removed.
*It is NOT RECOMMENDED to connect upstream of the sink or other waste water receptacle !
18
© Baxi Heating UK Ltd 2014
Boiler iii) Termination to a drain or gully
Pipe must terminate above water level but below surrounding surface. Cut end at 45°
50mm per metre of pipe run
2.5° Minimum fall
7.0 Site Requirement
7.6
Condensate Drain (cont.)
11. When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC's are flushed or sinks emptied then back-pressure may force water out of the boiler trap and cause appliance lockout.
Boiler iv) Termination to a purpose made soakaway
Further specific requirements for soakaway design are referred to in BS 6798.
500mm min
50mm per metre of pipe run
2.5° Minimum fall
Holes in the soak-away must face away from the building
© Baxi Heating UK Ltd 2014
19
v) pumped into an internal discharge branch
(e.g. sink waste) downstream of the trap
50mm per metre of pipe run
Sink
2.5° Minimum fall
Boiler
Basement or similar
(heated)
Condensate Pump
7.0 Site Requirement
Pipe must terminate above water level but below surrounding surface. Cut end at 45°
7.6
Condensate Drain (cont.)
12. A boiler discharge pump is available, ‘MULTIFIT’ part no. 720648301. This pump will dispose of both condensate & high temperature water from the relief valve.
It has a maximum head of 5 metres. Follow the instructions supplied with the pump.
13. Condensate Drain Pipe ‘Trace Heating’ Elements are available in various lengths. ‘MULTIFIT’ part nos.:-
1 metre 720644401
2 metre 720664101
3 metre 720664201
5 metre 720664401*
*Where the drain is between 3 & 5 metres a 5 metre kit can be used and “doubled back” upon itself.
14. It is possible to fit the element externally on the condensate drain or internally as detailed in the instructions provided.
15. The fitting of a ‘Trace Heating’ Element is NOT a substitute for correct installation of the condensate drain.
ALL requirements in this section must still be adhered to.
vi) pumped into an external soil & vent pipe
50mm per metre of pipe run
2.5° Minimum fall
Unheated Location
(e.g. Garage)
Basement or similar
(heated)
Boiler
Condensate Pump vii) to a drain or gully with extended external run & trace heating
Boiler
The ‘Trace Heating’ element must be installed in accordance with the instructions supplied.
External runs & those in unheated locations still require insulation.
50mm per metre of pipe run
2.5° Minimum fall
Pipe must terminate above water level but below surrounding surface. Cut end at 45°
20
© Baxi Heating UK Ltd 2014
Terminal Position with Minimum Distance (Fig. 17) (mm)
I
J
A1 Directly below an opening, air brick, opening windows, etc.
B1 Above an opening, air brick, opening window etc.
C1 Horizontally to an opening, air brick, opening window etc.
D2 Below gutters, soil pipes or drain pipes.
E2 Below eaves.
F2 Below balconies or car port roof.
G2 From a vertical drain pipe or soil pipe.
H2 From an internal (i) or external (ii) corner.
300
300
300
25 (75)
25 (200)
25 (200)
25 (150)
(i) 25 (300) (ii) 115
K
Above ground, roof or balcony level.
From a surface or boundary line facing a terminal.
From a terminal facing a terminal (Horizontal flue).
From a terminal facing a terminal (Vertical flue).
L From an opening in carport (e.g. door, window) into the dwelling.
M Vertically from a terminal on the same wall.
N Horizontally from a terminal on the same wall.
300
600
1200
600
R
S
T
U
From adjacent wall to flue (vertical only).
From an adjacent opening window (vertical only).
Adjacent to windows or openings on pitched and flat roofs
Below windows or openings on pitched roofs
1200
1500
300
300
1000
600
2000
1 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.
2 Only ONE 25mm clearance is allowed per installation. If one of the dimensions
D, E, F, G or H is 25mm then the remainder MUST be as shown in brackets, in accordance with B.S.5440-1.
NOTE: The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below
300 min
Terminal
Assembly
*
7.0 Site Requirements
7.7
Flue
NOTE: Due to the high efficiency 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. Take into consideration the effect the plume of vapour may have on neighbours when siting the flue.
4. Adjacent surfaces close to the flue terminal may need protection from the effects of condensation. Alternatively a flue deflector kit (part no. 248167) is available.
5. For installation of the flue into an internal corner at the
25mm dimension the flue deflector kit (part no. 248167) must be fitted.
6. * Reduction to the boundary is possible down to 25mm but the Flue Deflector Kit (part no. 248167) must be fitted.
7. If required a suitable terminal guard is available from Baxi for use with the flue deflector.
8. For fitting under low soffits and eaves the Plume
Displacement Kit or Flue Deflector Kit is recommended.
9. If a terminal is less than 2 metres (78 3 /
4 in) above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be provided.
IMPORTANT:
• Under car ports we recommend the use of the plume displacement kit.
• The terminal position must ensure the safe and nuisance - free dispersal of combustion products.
Top View Rear Flue
Fig. 17a
J,K
T
U
Property Boundary Line
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).
Plume
Displacement Kit
R
I
F
L
I
M
N
B
G
A
I
C
D
E
I
S
A
I
J,K
H
A
F
H
Likely flue positions requiring a flue terminal guard
Fig. 17
Air Inlet
© Baxi Heating UK Ltd 2014
Fig. 17b
150mm
MIN.
Opening Window or Door
21
Plume Displacement 70/110 dia Kit
1M Extensions, 45° & 93° bends are also available - see Section 9.0
Y
X
Horizontal
Flue System Examples
X
Y
8.0 Flue Options
8.1
Horizontal Flue Systems
Concentric
The maximum equivalent lengths are 4m (horizontal) or
(vertical). Their lengths exclude the standard elbow and flue/terminal assembly (horizontal) and terminal assembly
(vertical).
Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:
Concentric Pipes: 45° bend
93° bend
0.5 m
1.0 m
NOTE: Flue length is measured from point X to Y as shown.
IMPORTANT: All flue systems must be securely supported at least once every metre. Suitable pipe supports are available as accessories.
NOTE: Horizontal flue pipes should always be installed with a 1.5° fall from the terminal to allow condensate to run back to the boiler.
This bend is equivalent to
0.5 metre
B
A
Y
This bend is equivalent to
0.5 metre
X
Total equivalent length (up to 4m) =
A+B+2x45°Bends
22
© Baxi Heating UK Ltd 2014
Vertical Flue System
Examples (Twin Pipe)
Y
X
Vertical Flue
System Examples
Y
X
8.0 Flue Options
8.2
Twin & Vertical Flue Systems
Concentric
The maximum equivalent lengths are 4m (vertical). Their lengths exclude the standard elbow and terminal assembly
(vertical).
Twin Flue
The total maximum equivalent flue length is 150m.
NOTE: Each 1m of flue duct should be calculated as 2m.
Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:
Concentric Pipes: 135° bend
93° bend
Twin Flue Pipe:
0.5 m
1.0 m
135° bend (air duct)
135° bend (flue duct)
90° bend (air duct)
90° bend (flue duct)
1.3 m
2.6 m
4.8 m
9.6 m
IMPORTANT: All flue systems must be securely supported at least once every metre. Suitable pipe supports are available as accessories.
Total Equivalent Length =
A+B+C+1x90°Bend
All vertical and angled runs must be included, measured from the boiler adaptor (point X) to the joint with the flue terminal (point Y). One 91.5° bend or two 135° bends can be included without reduction of the flue length.
If further elbows are required the flue length must be reduced by the following amounts:-
Y
1 metre for each 91.5° bend
0.5 metre for each 135° bend
B
C
Roof
Terminal
This bend is equivalent to
1 metre
A
X
© Baxi Heating UK Ltd 2014
The total equivalent length for this example is
17.2 + 34.4 = 51.6 metres.
1m extension
135°bend
91.5°bend
Equivalent
Length Value
1m
1.3m
4.8m
AIR DUCT
N fittings/pipes
5
2
2 o of Sub total
5.0m
2.6m
9.6m
Equivalent Length Air Duct = 17.2m
1m extension
135°bend
91.5°bend
Equivalent
Length Value
2m
2.6m
9.6m
FLUE DUCT
N fittings/pipes
5
2
2 o of Sub total
10.0m
5.2m
19.2m
Equivalent Length Flue Duct = 34.4m
23
A
A1
B
E
C
D
T K
S
G F U,W
8.0 Flue Options
8.3
Flue Accessories
T
S
C
D
U
Key Accessory Size
FLUE GROUP B
Concentric Flue System 110mm diameter
Code No
A1 Horizontal Flue Terminal
A
850mm
Horizontal Flue Terminal (incl elbow)
B Flue Extension 1000mm
500mm
243013BAX
236921
241695
241694
Flue Bend
Flue Bend (pair)
Pipe Support
Vertical Flue Boiler Adaptor
Flue Terminal Deflector
250mm
93°
135°
110mm
241692
241687
241689
243014BAX
5106888
248167
FLUE GROUP P
Twin Flue System 80mm diameter
E Flue Extension 1000mm 246137
500mm 246136
250mm
90°
246135
5121560 F
J
G
Flue Bend (pair)
Flue Bend (2 pair)
Vertical Flue Boiler Adaptor Kit
W Pipe Support (pair)
135°
80mm
5121561
242757
5111081
K
L
FLUE GROUP B,P
Vertical Flue Kits
Vertical Flue Terminal
Pitched Roof Flashing
M
N
Roof Cover Plate
Flat Roof Flashing
25°/50°
242802
243015
243131
243016BAX
M
L
N
24
© Baxi Heating UK Ltd 2014
J
Vertical Flue
Adaptor
Gasket
Air Duct
Adaptor
Gasket
For Vertical Flues
8.0 Flue Options
8.4
For Vertical Flue Systems
1. Undo the screws securing the blanking plate to the boiler top panel. Discard the plate.
2. Fix the vertical adaptor and gasket to the top panel with the previously removed screws.
8.5
For Twin Flue Systems
1. Undo the screws securing the blanking plate to the boiler top panel. Discard the plate.
2. Fix both the air and flue adaptors with their gaskets onto the boiler top panel. Secure with screws.
For Twin Flues
Flue Duct
Adaptor
Gasket
© Baxi Heating UK Ltd 2014
25
Cut the same amount off the
Air Duct &
Flue Duct
Fig. 19
26
© Baxi Heating UK Ltd 2014
270mm
Fig. 18
800mm
Air Duct
Flue Duct
Approx
1425mm
Push Fit Adaptor
Flue Deflector
Fig. 18a
8.0 Flue Options
8.6
For Roof Terminals
1. In the case of a pitched roof 25 - 50 degrees, position the lead tile to replace/flash over existing roof tiling. Make an aperture in the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained. The adjustable plastic collar can either be positioned on the lead tile or the lower tube of the roof terminal prior to the final positioning of the vertical flue through the tile. Check the collar is correctly located to suit required roof pitch (either 25° to 38° or 37° to 50°). From inside the roof adjust the flue to a vertical position and secure to the roof structure with the clamp supplied.
2. For flat roof installations the aluminium flashing must be incorporated into the roof covering and the appropriate aperture made in the roof decking. The vertical flue is lowered onto the flashing making sure the collar of the flue locates securely with the flashing. (A mastic seal may be necessary). From inside the roof, adjust the flue to a vertical position and secure to the roof structure with the clamp supplied.
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 flue lengths between 270mm (10 5 /
8
”) and 800mm (32”) from elbow to terminal (Fig. 18).
The maximum permissible equivalent flue length is: 4 metres.
NOTE: Each additional 45° of flue bend will account for an equivalent flue length of 0.5m.
e.g. 45° = 0.5m, 90° = 2 x 45° = 1m etc.
8.8
Terminal Guard (Fig. 19)
1. When codes of practice dictate the use of terminal guards, they can be obtained from most Plumbers’ and
Builders’ Merchants.
2. When ordering a terminal guard, quote the appliance model number.
3. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated.
8.9
Flue Deflector (Fig. 18a)
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.
Plume Outlet (‘Peak’
MUST be Uppermost)
0.94 metre
Fig. A
Outlet Connection upwards
© Baxi Heating UK Ltd 2014
Fig. C
45°
45°
Outlet must be at least 45° from wall face
‘Peak’ MUST be
Uppermost
500mm Min.
Fig. B
9.0 Plume Displacement
9.1
Plume Displacement Kit (P.D.K.)
Kit No 5121371
Content of kit
1 70/110 Concentric Flue
1 1m 70 Dia Exhaust Flue Pipe
2 Support Brackets
1 93° Elbow/Plume Outlet Assembly
1 Flue Trim
2 “O” Rings
1 Elbow with Gasket
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 outlet connection upwards.
3. The 70Ø pipe connects to the outlet of the concentric terminal assembly. The elbow/plume outlet must be fitted to the end of the 70Ø pipe.
NOTE: The plume outlet must always be at least 45° to the wall, with the ‘peak’ uppermost to prevent rain entry
(Figs. A & B), and be at least 2 metres above ground level.
It must be secured as shown in Fig. C.
The outlet must be positioned so that any condensate plume is directed away from adjacent surfaces.
4. It is possible to reduce or increase (with the addition of extensions) the length of either or both the 70/110 concentric and 70Ø 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 boiler flue elbow. There is a further 45mm engagement into the elbow.
IMPORTANT: The maximum equivalent length of concentric flue is:- 4 metres
Additional elbows 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. 70Ø 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. 70Ø 93° elbows are equivalent to 3.5 metres of straight length and 45° elbows to 1 metre.
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.
27
18
16
14
12
10
30
28
26
24
22
20
12,
15,
18 & 24
30
4
2
8
6
0
0
Example 1
1 2 3
Concentric 70/110 Flue (metres)
4
Flue Lengths - Not Permissible
30
28
26
24
22
20
18
16
14
12
10
8
6
12,
15,
30
18 & 24
4
2
0
0 1 2 3
Concentric 70/110 Flue (metres)
4
Example 3
Flue Lengths - OK
20
18
16
14
30
24
22
28
26
12
10
8
6
12,
15,
18 & 24
30
4
2
0
0
Example 2
1 2 3
Concentric 70/110 Flue (metres)
4
Flue Lengths - OK
70Ø Exhaust
9.0 Plume Displacement
Support
Bracket
9.2
Determining Permissible Lengths - P.D.K.
In the graph the solid line diagonal represents the relationship between the concentric flue assembly (and any extensions) and the 70Ø exhaust (and any extensions or additional bends).
Example 1 - Not Permissible
If, for instance, a concentric length of 3.25 metres was required and the 70Ø exhaust needed to be 10 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 70Ø 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 metres long. Find the position of ‘2’ 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 14 metres.
Therefore, the total equivalent length of the 70Ø exhaust can be up to 14 metres. Any elbow equivalencies must be accounted for i.e. 93° elbows are equal to 1 metre, each 45° elbow to 0.5 metres.
45° Elbow
Y
X
Concentric 70/110 Flue
(MUST be installed horizontally)
Additional Accessories
A - 93° Elbow
B - 45° Elbow (Pair)
5121373
5121374
C - 1 metre 70Ø Extension 5121372
93° Elbow
Concentric Flue
1 metre Extension
1 metre supplied in kit
Flue Length - Worked Example
Potterton Promax 30 SL
In Fig. D opposite an additional 93° elbow and pair of 45° elbows have been included in the 70Ø exhaust.
Also 3 straight extension pieces have been used.
To calculate total length:-
Length of 70Ø supplied in kit = 1 metre
3 x 1 metre Extensions =
1 x 93° Elbow =
2 x 45° Elbow =
3 metres
1 metre
1 metre (0.5 metres each)
Total 70Ø = 6 metres
After consulting the table in Example 3 it can be determined that the concentric flue could be up to approximately 3.25
metres long.
Fig. D
28
© Baxi Heating UK Ltd 2014
Min. 2 metres
Fig. G
© Baxi Heating UK Ltd 2014
Min. 0.3 metres
Fig. F
This section of the flue MUST be horizontal
Fig. E
9.0 Plume Displacement
9.3
General Fitting Notes - P.D.K.
1. Cut a hole in the external wall which the horizontal concentric flue assembly will pass through.
2. When completed the terminal must be at least 2 metres above ground level (Fig. E).
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 and mark the position of the flue trim securing holes.
5. Drill and plug the wall to accept the flue trim securing screws, and re-insert the concentric assembly through the wall.
6. Connect any extensions that are being used to the concentric assembly. Engage the extension or concentric assembly in the boiler flue elbow.
7. Fit the boiler flue elbow to the boiler top panel, ensuring the gasket is in place (Fig. F).
Ensure that the concentric assembly is horizontal and that the external air inlet is to the bottom. Any extensions should fall back to the boiler.
8. Use suitable brackets to support the concentric assembly and any extensions, and make good inside and outside.
Secure the flue trim to the wall.
9. The 70Ø exhaust can now be fitted to the spigot at the terminal end.
10. If it is necessary to shorten the 70Ø 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 70Ø exhaust and mark on the wall a suitable position for the support bracket. Drill and plug the wall. If extensions are being used, a support bracket is supplied in each kit.
12. Engage the M6 threaded part of the mounting bolt in the boss on the support bracket. Using the bracket for leverage, screw the mounting bolt into the plugged hole until the bracket is secure and level (Fig. G).
13. Slacken the two screws securing the retaining strap to the bracket, and pivot the strap aside to allow fitting the
70Ø exhaust.
14. Complete the installation of the 70Ø exhaust, securing in the brackets. Fit the 93° elbow and plume outlet. Ensure the plume outlet is at least 45° to the wall and that the
‘peak’ is uppermost.
15. Continue with installation and commissioning of the boiler.
29
Fig. I
200mm Min.
Fig. J
30
© Baxi Heating UK Ltd 2014
Plume Outlet
Fig. H
200mm Min.
500mm Min.
Elbow
9.0 Plume Displacement
9.3
General Fitting Notes - P.D.K.
(cont.)
16. For aesthetic purposes it is permissible to route the
70Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air.
17. It is also possible to separate the plume outlet from the 93° elbow to allow the flue to be installed as shown in Fig. H.
18. When the plume outlet is positioned under a balcony or other projection (Figs. I & J) it must protrude at least
200mm (it is not necessary to extend it further than this).
Template
Literature Pack
10.0 Installation
Wall Plate
Edge of Boiler
Example
2m
Horizontal
Side Flue
Centre Line
Fig. 19a
96mm
Example
V = 55mm
EXAMPLE: Boiler is 2 metres away from corner of wall, flue duct hole is
55mm up from horizontal side flue centre line. This will maintain the approx 1.5° backfall to the boiler.
Check Site Requirements (section 7) before commencing.
10.1
Initial Preparation
The gas supply, gas type and pressure must be checked for suitability before connection (see Section
7.4).
1. Cut the banding and remove the fixing template, wall plate and literature pack (Fig. 19a) from the carton.
2. After considering the site requirements (see Section
7.0) position the template on the wall ensuring it is level both horizontally and vertically.
NOTE: When fitting Plume Displacement Kit refer to the instructions supplied for details of installation of the flue.
3. Mark the position of the fixing holes for the wall plate (Fig. 20).
Fig. 20
Flue Duct Hole
Offset V (mm)
Backfall to the Boiler, ie. 2m flue offset (V) position 55mm
13.5
27.5
55 82.5
110 (mm)
V
Wall Plate Template
Wall Thickness up to 227mm up to 750mm up to 1200mm
Flue Hole ø
127mm core drill
150mm core drill
175mm core drill
1.5
°
4. Mark the centre of the flue hole (rear exit).
For side exit: project the horizontal side flue centre line into the corner of the room and along the wall to where the flue hole will be drilled. (Fig. 20).
The diagram (Fig. 21) shows the dimensions required to ensure any horizontal flue is installed with the correct fall to the boiler. Mark the offset (V) dimension and if required, mark the position of the gas and water pipes.
Remove the template.
5. Cut the hole for the flue (minimum diameter
127mm, see table (Fig. 20) for wall thicknesses and flue diameters).
6. Drill and plug the wall as previously marked. Secure the wall plate (Fig. 22).
0.5
1.0
2.0
3.0
4.0
(metres)
Distance in metres from boiler to the wall.
For pipe lengths greater than 4m increase the off-set by 26mm for every additional metre to maintain approx 1.5
° inclination.
7. Ensuring the wall plate is level both horizontally and vertically, drill and plug at least 5 securing positions at the top and bottom through the wall plate. Utilising the slots available ensure the wall plate is square and secure to the wall (Fig. 22).
8. Additionally drill 2 relief holes 10mm deep in the wall as shown on template (Fig. 22).
Fig. 21
8. Loosely route the condensate discharge pipe to the lower left hand side of the wall plate.
Relief Holes
Wall Plate
Fig. 22
© Baxi Heating UK Ltd 2014
31
Lower Door Panel
Fig. 22a
Internal Polystyrene
Packaging Piece
Outercase
10.0 Installation
10.2
Preparing The Boiler
1. Remove the outer carton and packaging.
2. Lift the outercase upwards and remove.
3. Remove the internal packaging.
Break Off Upper &
Lower Pipe Run
Options
Fig. 23
32
© Baxi Heating UK Ltd 2014
Suggested Lifting
Points shown as shaded area
Flue Products Exhaust
Fig. 25a
Retaining Bracket
Remove the red pipe protection caps
Fig. 24
Wall Plate
Return Pipe Connection
Flow Pipe
Connection
Fig. 25
10.0 Installation
10.3
Fitting The Boiler
(Fig. 24)
1. Obtain retaining bracket and two M6 nuts from fitting bag.
2. Offer up the boiler to the wall plate using the lifting points shown in Fig. 24 and locate the rear bottom edge onto the self locating support at the base of the wall plate.
(See Safe Manual Handling page 5.)
NOTE: When installing in a Loft/Small Compartment, access for lifting the boiler from the front can be gained for two people using the lifting points. (Fig. 24).
3. Rotate the boiler up to wall plate and engage retaining bracket, securing with the two nuts.
4. Ensure the boiler is secured with the retaining bracket.
5. Remove red pipe protection caps from the FLOW and
RETURN connections.
10.4
Making the Water Connections
(Fig. 25)
1. The boiler has two side water connections which are labelled FLOW and RETURN. The front connection is the flow pipe and the rear threaded connection is the return.
2. It is essential that the flow and return pipes are connected to the boiler correctly. The flow connection incorporates the boiler thermostats and a flow switch.
3. The boiler connections will accept 22mm fittings.
NOTE: On 30 models 28mm pipe should be used to connect to the boiler flow and return using suitable reducing fittings.
4. If the installation requires that the system pipework originates from the bottom of the boiler, then the flow and return pipes will need cutting, as they terminate upwards.
10.5
Making the Condensate Drain Connection
1. Connect the condensate drain using the 1”BSP nut and seal supplied. (see section 7.6).
NOTE: To ensure the correct operation and integrity of the condensate drainage system -
Carefully pour approximately 1 cupful (250ml) of water into the flue products exhaust, at the top of the heat exchanger (Fig. 25a) to ensure a seal is made in the trap.
© Baxi Heating UK Ltd 2014
33
At Least 1.5°
Fig. 26
Waste
Fig. 27
Wall Thickness
10.0 Installation
10.6
Making the Gas Connection
1. Connect the gas supply to the G 1 /
2
( 1 /
2 in BSPT
Internal) gas tap. This is located on the lower right side of the boiler, access by hinging down the PCB housing
(see Fig. 32).
(Z) = Side Exit
(X) = Rear Exit
Flue
(Z)
360° Orientation
Inner Flue Support Bracket
Edge of Wall Plate to Wall
Wall Thickness
Fig. 27a
10.7
Fitting The Flue
Before fitting the flue, check the condensate drain integrity (see section 10.5).
IMPORTANT: The flue should always be installed with at least 1.5° fall from terminal to elbow, to allow condensate to run back to the boiler.
HORIZONTAL FLUE
1. The standard flue is suitable for lengths 270mm minimum to 800mm maximum (measured from the edge of the flue elbow outlet).
Rear Flue: maximum wall thickness - 630mm
Side Flue: maximum wall thickness - 565mm (left or right)
2. For rear exit - measure the wall thickness
(Fig. 26) and to this dimension add 181mm. This dimension to be known as (X).
i.e.
(X) = wall thickness + 181
3. Take the flue and mark off (X) from the terminal end as indicated in the diagram (Fig. 27).
Check your dimensions.
The flue tubes are fixed together. Cut through both tubes whilst resting the flue on the semi-circular packing pieces. Deburr both tube ends.
4. For side exit - measure the distance from the edge of the wall plate to the inner face of the wall (Fig. 26) and to this dimension add the wall thickness + 250mm.
This dimension to be known as (Z).
i.e.
(Z) = wall plate to wall + wall thickness + 250
5. Take the flue and mark off (Z) from the terminal end as indicated (Fig. 27).
Check your dimensions.
The flue tubes are fixed together. Cut through both tubes whilst resting the flue on the semi-circular packing pieces. Deburr both tube ends.
IMPORTANT: Check all measurements before cutting.
NOTE: When cutting ensure the cut does not interfere with the inner flue support bracket
(Fig. 27a).
34
© Baxi Heating UK Ltd 2014
Fig. 29a
Flue Elbow
Inner Flue Support Bracket
Flue
Tape (Rear Flue Only)
Fig. 28
Apply Lubricant for ease of assembly. Ensure Flue is fully engaged into Flue Elbow
Gasket
10.0 Installation
10.7
Fitting the Flue (Cont)
6. Ensure the inner flue support bracket is positioned in the flue (Fig. 28).
7. Engage the flue into the flue elbow using soap solution to ease the engagement ensuring the flue is assembled as shown (Fig. 29). Rear flue only:- Take the tape supplied in the kit and wrap around the joint between the flue and the elbow (Fig. 29a).
8. Place the gasket over the flue exit on the boiler.
9. Slide the flue assembly through the hole in the wall.
10. Engage the elbow on to the flue connection on top of the boiler. Secure with the four screws supplied in the kit.
11. Make good between the wall and air duct outside the building ensuring the 1.5° drop between the terminal and elbow.
12. The flue trim should be fitted once the installation is complete and the flue secure (Fig. 30). Apply a suitable mastic to the inside of the trim and press against the wall finish, making sure the brickwork is dust free and dry.
13. If necessary fit a terminal guard (see Section 8.8).
VERTICAL FLUEING
1. Only a flue approved with the Potterton Promax SL range can be used.
Flue Trim
Fig. 30
Fig. 29
© Baxi Heating UK Ltd 2014
35
Hinge down
PCB Housing
Fig. 31
Cable Clamp
Blue (CN11) Jumper
Red (CN12) Jumper
Fig. 32
10.0 Installation
10.8
Making The Electrical Connections
WARNING: This appliance must be earthed
1. The electrical connections are on the right hand side of the unit.
2. Undo the two screws securing the cable clamp and place to one side (Fig. 31).
3. The Promax 30 SL is factory set to give a maximum output of 22.0 kW (75,000 Btu/hr). The Control PCB jumper positions are as follows:
CN11 (Blue) CN12 (Red)
If the installation requires a greater output to achieve the desired room temperature, this can be increased to 30.18
kW (103,000 Btu/hr) and the boiler can be adjusted as follows (Fig. 32): a) Remove the top right hand securing screw and hinge down the PCB housing.
b) Remove the Red jumper labelled CN12 from the bottom left hand side of the PCB.
c) Hinge back up the PCB housing and secure with screw.
4. Route the incoming electrical cable/s through the grommet in the support bracket. This will prevent damage to the cable.
5. Lay the cable through the cable clamp to gauge the length of cable required when it is connected to the 4-way terminal block.
6. Connect the (S/L), (N) and ( ) wires to the
4-way terminal block (Fig. 33) and refit the cable clamp
(Fig. 31).
7. Check the electrical installation for; earth continuity, short circuits, resistance to earth, correct polarity and fuse failure.
4-way Terminal Block
S/L
Fig. 33
36
© Baxi Heating UK Ltd 2014
N P/F
Optional Pump Feed Connection only required for fully TRV’d system
11.0 Electrical
11.1
Schematic Wiring Diagram
Earths not shown to aid clarity of diagram
PCB op g gy gy
CH
Flow
Switch
325 Vdc
DC Fan op w g br g/y b r bk r w r
Flow
Thermistor r br b y
Flow
Overheat
Thermostat bk g/y g/y br b
L N Optional
Pump
Feed bk
Fan
Overheat
Thermostat bk
Gas
Valve w op
Flame
Detection
Spark
Electrode
Electrode
Condensate
Trap g/y
Key To Wiring Colours b - Blue bk - Black w - White br - Brown gy - Grey r - Red g - Green g/y- Green/Yellow op - Opaque y - Yellow
© Baxi Heating UK Ltd 2014
37
11.0 Electrical
11.2
Illustrated Wiring Diagram gy gy
Layout of PCB Pins
CH
Flow Switch
r
Flow
Thermistor
y b g/y r y b br
Optional
Pump
Feed
N
L b br
Spark
Electrode
Flame
Detection
Electrode
g/y br br
Main
PCB
w op w
Condensate Trap
g/y br w g r b
Fan
bk bk r bk bk
Gas Valve
Fan Overheat
Thermostat
Flow Overheat
Thermostat
Wiring Key b - Blue bk - Black br - Brown r - Red w - White g/y - Green/Yellow g - Green gy - Grey op - Opaque y - Yellow
38
© Baxi Heating UK Ltd 2014
Fig. 35
Reset
High
ON
Low
DO NOT check gas pressure here
Gas Service
Cock
Flow Temperature
Adjustment Screw
Open
Fig. 34
12.0
Commissioning the Boiler
12.1
Commissioning the Boiler
WARNING: The PCB Control and Fan
Assembly are 325 Vdc. Isolate at supply before access.
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. Flush the whole system using a suitable flushing agent
(see Section 6.2) and vent the radiators. Check for water leaks.
4. Refill the system with inhibitor following the inhibitor manufacturer’s instructions and BS 7593 Code of Practice for Treatment of Water in Domestic Hot Water Central
Heating Systems (see Section 6.2).
5. Complete the label supplied with the inhibitor and attach to the inside of the boiler case. Detail of system treatment should be added for future reference.
6. Turn the gas supply on and purge according to in GB
BS 6891 and in IE I.S. 813 “Domestic Gas Installations”.
7. Remove the top RH securing screw and hinge down the PCB housing to gain access to the gas service cock
(see Fig. 32). Turn the gas service cock anticlockwise to the ON position and check for gas tightness up to the gas valve (Fig. 34).
NOTE: The 12,15,18,24 are self-regulating dependent upon the system load. The 30 will modulate between inputs of 33.76kW and 10.3kW.
The 30 input is factory set at 24.5kW and can be altered to 33.76kW - see section 10.8. No adjustment of the gas valve is permissible.
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.
8. 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:
Inlet Gas Pressure Test Point
Fig. 36
© Baxi Heating UK Ltd 2014
39
Perform Flue Integrity
Visual Check
Examine all flue joints for soundness and ensure the system is adequately supported.
12.0
Commissioning the Boiler
12.2
Checking the Combustion
1. This procedure is mandatory in GB from April 2014. It is strongly recommended to perform the procedure before that date.
Rectify all faults
If necessary call
0844 871 1555 for advice.
The appliance MUST NOT be commissioned until all problems are resolved.
No
Is flue system OK ?
Yes Set Boiler to Maximum Rate*
Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser.
Check CO & Combustion
Ratio at Maximum Rate
Whilst the boiler is still operating at maximum insert the analyser probe into the flue gas test point, allowing the reading to stabilise.
*To operate at Maximum Rate
Ensure all external controls are calling for heat, that the system is cold and the boiler control knob is turned fully clockwise.
Verify Integrity of Seals
Check all burner seals, internal flue seals, door & case seals.
Replace any seals that appear unsound.
No
Is CO < 350ppm and CO/CO
2 ratio < 0.004 ?
Is CO < 350ppm and CO/CO
2 ratio < 0.004 ?
No
Yes
Yes
Set Boiler to operate at a low rate. If it is not possible to adjust the boiler to run at minimum rate using the boiler controls, the system must be set such that the boiler will modulate to as low an input as possible without the burner extinguishing (e.g. by closing radiator valves)
Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser.
The gas rate must be checked & recorded whilst the boiler is operating in this condition.
TURN APPLIANCE OFF !
Call 0844 871 1555 for advice.
The appliance MUST NOT be commissioned until all problems are identified and resolved.
If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with the GSIUR.
Note: Check & record the CO
& combustion ratio at both maximum & a low rate before calling 0844 871 1555.
No
Is CO < 350ppm and CO/CO
2 ratio < 0.004 ?
Yes
BOILER OPERATING
SATISFACTORILY. NO
FURTHER ACTION
REQUIRED
Ensure test points are capped, the boiler case front panel is correctly fitted & secured and all other commissioning procedures completed.
Complete the ‘Benchmark’
Checklist, recording the
CO & combustion ratio readings as required.
40
© Baxi Heating UK Ltd 2014
DO NOT check gas pressure here
Inlet Gas Pressure Test Point
Fig. 36a
12.0 Commissioning the Boiler
12.3
Check the Operational (Working) Gas
Inlet Pressure
1. Ensure that all controls are calling for heat and maximum load is applied to the system.
2. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point is in accordance with B.S. 6798 & B.S. 6891.
3. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working.
Measure the Gas Rate
4. With any other appliances & pilot lights turned OFF the gas rate can be measured. It should be as shown in
Section 4.0 Technical Data.
5. 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.
6. 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.
© Baxi Heating UK Ltd 2014
41
Outercase Securing
Screws
Break Off Panel
Lower Door Panel
Fig. 37
Fig. 38
13.0
Fitting the Outer Case
13.1
Fitting The Outer Case
1. Position the outercase over the boiler engaging the lugs in the side flanges over the hooks on the wall plate.
Break off top or bottom panel as required to accommodate pipework runs (Fig.37).
2. Using the two screws supplied in the kit, secure the outercase to the combustion box (Fig. 37).
3. Hinge up the lower door panel (Fig. 38).
4. The “Important Ventilation Information” label can be removed unless the appliance is installed in an unventilated compartment.
5. 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 may 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.
For IE, it is necessary to complete a “Declaration of
Conformity” to indicate compliance to 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.
6. Instruct the user in the operation of the boiler controls. Hand over the User’s Operating, Installation and Servicing Instructions, giving advice on the necessity of regular servicing.
7. Demonstrate to the user the action required if a gas leak occurs or is suspected. Show them how to turn off the gas supply at the meter control, and advise them not to operate electric light or power switched, and to ventilate the property.
8. Show the user the location of the system control isolation switch, and demonstrate its operation.
9. Advise the user that they may observe a plume of vapour from the flue terminal, and that it is part of the normal operation of the boiler.
10. Complete the label supplied with the inhibitor and stick to the inside of the boiler case. Detail of system treatment must be recorded in the Benchmark
Commissioning Checklist.
42
© Baxi Heating UK Ltd 2014
© Baxi Heating UK Ltd 2014
14.0 Servicing the Boiler
14.1
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 14.2.
• The operational gas inlet pressure as described in Section
12.3.1 to 12.3.3 and the gas rate as described in 12.3.4.
• The combustion performance as described in ‘Check the
Combustion Performance’ (14.1.4 to 14.1.6 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
2 ratio)
4. Set the boiler to operate at maximum rate as described in
Section 12.2.
5. Remove the cap from the flue sampling point, insert the analyser probe and obtain the CO/CO
2 ratio. This must be less than 0.004.
6. If the combustion reading (CO/CO
2 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 14.2) & re-check.
• Replace the gas valve (Section 15.8) & re-check.
43
Air Box Door Panel
Earth
Spark
Sleeve
Sensing
Fig. 40
Lead Terminals
Fig. 39
14.0
Servicing the Boiler
14.2
Annual Servicing - Inspection
1. Ensure that the boiler is cool.
2. The boiler cannot be switched off at the boiler, therefore it is important to isolate the electrical supply at the mains fuse.
3. Hazardous materials are not used in the construction of these products, however reasonable care during service is recommended.
4. When replacing the combustion box door after servicing it is essential that the retaining screws are tightened fully.
5. Ensure that both the gas and electrical supplies to the boiler are isolated.
6. Remove the outercase and lower door panel (see Fitting the
Outercase, Section 13.0).
WARNING: The PCB Control and Fan
Assembly are 325 Vdc. Isolate at supply before access.
7. Release the four 1 /
4 turn screws securing the air box door panel and remove the door (Fig. 39).
8. Disconnect the leads from the centre and right hand terminals (earth and flame sensing probe) (Fig. 40). Reconnect in reverse order.
9. Undo the four screws securing the combustion box door and remove the door (Fig. 41).
10. Visually check for debris/damage and clean or replace if necessary the following: a) Burner.
b) Heat exchanger fins.
c) Fan compartment
(Check also for condensate leaks).
d) Insulation.
e) Door seals-Important: Pay particular attention to the condition of the combustion box door seals.
f) Electrodes.
g) The condensate trap
NOTE: Remove the trap drain plug and place a vessel underneath to catch the condensate (care should be taken as this could be hot). Clean the trap and refit the drain plug. Check for leaks.
h) Top of heat exchanger.
Combustion Box
Door Panel
Fig. 41
44
© Baxi Heating UK Ltd 2014
14.0
Servicing the Boiler
Injector Pipe
Injector Pipe Retaining
Screw
Flue Sampling Point
Fig. 41a
Combustion
Box Base
Heat Exchanger
Support Bracket
Burner Securing
Screws
Combustion Box Base
Securing Screws
Fig. 44
© Baxi Heating UK Ltd 2014
Fan
Protection
Sensor Leads
Fig. 42
Wing Nuts
Sensor
Leads
Electrical Supply
Condensate
Trap
Lock Nut
Central Insulation Panel
Burner
Condensate
Drain Pipe
Fig. 43
Securing Nut
14.1
Annual Servicing - Inspection (Cont)
11. To clean the heat exchanger and burner proceed as follows: a) Disconnect the electrical leads to the fan component protection sensor (Fig. 42).
b) Loosen the screw retaining the gas injector pipe at the venturi (Fig. 42).
c) Undo the two wing nuts to disconnect the fan
(Fig. 42).
d) Remove the fan and disconnect the electrical supply to it (Fig. 42).
e) Remove the gas injector pipe from the gas valve
(push-fit) (Fig. 42).
f) Undo the condensate trap securing nut, lock nut and the condensate drain pipe. Remove the condensate trap and disconnect the sensor leads (Fig. 43).
g) Remove the two screws securing the burner and remove the burner. Visually inspect the internal burner baffle for obstruction, check seal around baffle for cracks/damage. Clean with a soft brush. h) Loosen the two screws retaining the heat exchanger support bracket and slide to the left to remove
(Fig. 44).
i) Remove the four screws securing the heat exchanger/combustion box base and withdraw the base.
Service Drain
Plug j) Lower the central insulation panel and check condition (Fig. 44). Replace the lower insulation pad if necessary.
k) Ensure the heat exchanger fins are clear of any obstruction.
l) Check condition of all seals. Important: Pay particular attention to the condition of the combustion box door seals.
m) Reassemble in reverse order and check for leaks.
12. Check the CO/CO 2 ratio and CO 2 level at the flue sampling point (Fig.41a) is as quoted in Section 4.0,
‘Technical Data’.
13. If the ratio or level is greater than that quoted telephone the Technical Enquiries for further advice.
IMPORTANT: No adjustment of the gas valve is permissible.
14. 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.
45
Safety
Thermostat
Fig. 46
46
© Baxi Heating UK Ltd 2014
15.0
Changing Components
Fig. 45
Heat Exchanger
Manifold
Drain Point
Electrical Connections
Tube
Flow Temperature Thermistor
15.1
Changing Components
IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started.
“The boiler cannot be switched off at the boiler, therefore it is important to isolate the electrical supply at the mains fuse.”
Hazardous materials are not used in the construction of these products, however reasonable care during service is recommended.
When replacing the combustion box door after changing components, it is essential that the retaining screws are tightened fully.
After Changing Components a combustion check should be performed (see Section 15.8.11). This is especially important on gas carrying parts, and those that may affect combustion (e.g. fan).
1. Before changing any components please read Section
1.2 Important Information.
2. Remove the outer case and lower door panel (see
“Fitting the Outercase” Section 13.0).
WARNING: The PCB Control and Fan
Assembly are 325 Vdc. Isolate at supply before access.
3. Isolate the water circuit and drain the system as necessary. A drain point is located on the heat exchanger manifold at the right hand side of the boiler
(Fig. 45) to enable the heat exchanger to be drained.
4. Place a tube on the drain point to drain water away from electrics. Turn anticlockwise to open (Fig. 45).
NOTE: When reassembling always fit new ‘O’ rings, ensuring their correct location on the spigot. Green
“O” rings are used for gas joints and Black “O” rings for water joints. Use Greasil 4000 (Approved
Silicone Grease).
5. After changing a component re-commission the boiler where appropriate and check the inhibitor concentration (see Section 6.2 and 12.1).
The thermistor, safety thermostat, interface PCB and the flow switch can be accessed after removal of the outer case.
15.2
Flow Temperature Thermistor and
Safety Thermostat
(Fig. 46)
1. The procedure is the same for both the thermistor and the safety thermostat.
2. Remove the electrical connections from the sensor.
3. Unscrew the sensor from the pipe.
4. Fit the new thermistor or safety thermostat and reassemble in reverse order.
Support Bracket
Flow Switch
Clip
Fig. 47
Flow Pipe
15.0
Changing Components
15.3
Flowswitch
(Fig. 47)
1. Drain the boiler (see Section 15.1 paragraph 2 & 3).
2. Remove the two screws on the support bracket.
3. Remove the clip securing the flow pipe to the flowswitch.
4. Disconnect the inline electrical connection.
5. Pull pipe away from flowswitch.
6. Remove the two screws securing the flowswitch to the boiler.
7. Remove the flowswitch.
8. Fit the new flowswitch and reassemble in reverse order.
9. Recommission the boiler and check the inhibitor concentration (see Section 6.2 and 12.1).
© Baxi Heating UK Ltd 2014
47
Plastic
Button
Cover
Fig. 48
Hinge down
PCB Housing
Blue (CN11) Jumper
Red (CN12) Jumper
Fig. 49
PCB Housing Securing
Screw
15.0
Changing Components
15.4
PCB
(Figs. 48 & 49)
WARNING: The PCB Control and Fan
Assembly are 325 Vdc. Isolate at supply before access.
1. Remove the plastic button cover. Refit them onto the new PCB (Fig. 48).
1. Remove the top right hand securing screw and hinge down the PCB housing and disconnect the electrical connections noting their positions
NOTE: Check the PCB for the presence of input jumpers - see section 10.8. Set the new PCB as the one removed.
2. Lift Control PCB housing out of hinge housing of metal bracket.
3. Fit the new PCB Housing Assembly and reassemble in reverse order.
48
© Baxi Heating UK Ltd 2014
Earth
Spark
Air Box Door Panel
Sensing
Fig. 51
Combustion
Box Door
Injector Pipe
Screw
Injector
Opening
Gasket
Fig. 50
Fan
15.0
Changing Components
The fan and venturi, gas valve, injector pipe, condensate trap, fan protection sensor, spark and sensing electrodes can be accessed and changed on the removal of the airbox door panel.
1. Remove the airbox door panel by loosening the four
1 /
4 turn screws (Fig. 50).
15.5
Spark and Sensing Electrodes
(Fig. 51)
1. Disconnect all three leads from tabs.
Spark Opaque cable
Earth
Sensing -
Green/Yellow cable
White cable
2. Remove the two screws securing each of the electrodes to the combustion box door and remove the electrodes.
3. Fit the new electrodes (and new gasket, as required) and reassemble in reverse order.
15.6
Fan
(Fig. 52)
WARNING: The PCB Control and Fan
Assembly are 325 Vdc. Isolate at supply before access.
1. Loosen the screw holding the injector pipe into the venturi.
2. Remove the electrical connections to the fan and protection sensor on the fan.
3. Remove the wing nuts securing the fan to the base of the combustion box.
4. Lower the fan and remove.
5. If changing the fan remove the screws securing the venturi and fan protection sensor bracket, noting the positions of the injector opening and sensor bracket, fix them to the new fan.
6. Fit the new fan and reassemble in reverse order.
The injector pipe, condensate trap and gas valve can be changed after the removal of the fan.
Protection
Sensor
Electrical Connections
Venturi
© Baxi Heating UK Ltd 2014
Fig. 52
Wing Nuts
Electrical Connection
49
Injector Pipe
Boiler Side
Fig. 53
Sensor
Leads
Securing
Nut
Gas Valve
Securing Screws
Condensate
Trap
Lock Nut
Condensate
Drain Pipe
50
© Baxi Heating UK Ltd 2014
Service Drain
Plug
Fig. 54
Case Pressure Pipe
Gasket
Aluminium
Spacer
‘O ring’
Electrical Plug
15.0
Changing Components
The removal of the fan is necessary to enable the changing of the injector pipe, condensate trap and gas valve (see section 15.6).
15.7
Injector Pipe (Fig. 53)
1. Remove the injector pipe by pulling out from the ‘O’ ring joint in the gas valve.
2. Fit the new injector pipe and reassemble in reverse order.
Gas Valve
Gas Tap
15.8
Gas Valve (Fig. 53)
1. Remove the Control PCB (see Section 15.4).
2. Isolate gas supply and disconnect the gas tap by removing the four screws.
3. Undo the case pressure pipe from the gas valve.
4. Disconnect the electrical plug from the gas valve.
5. Remove the fan (see section 15.6) and injector pipe.
6. Remove the two gas valve securing screws from inside the air box holding the gas valve.
7. Remove the gas valve from the airbox side.
8. Remove the aluminium spacer and its gasket from the gas valve.
9. Fit the aluminium spacer and gasket to the new valve.
10. Fit the new gas valve and reassemble in reverse order.
NOTE: Check for gas tightness after replacing gas valve.
11. Check the CO/CO 2 ratio and CO 2 level at the flue sampling point (Fig.41a) is as quoted in Section 4.0,
‘Technical Data’.
12. If the ratio or level is greater than that quoted, telephone the Technical Enquiries for further advice.
IMPORTANT: No adjustment of the gas valve is permissible.
15.9
Condensate Trap (Fig. 54)
1. Disconnect the condensate trap from the base of the heat exchanger.
2. Disconnect the condensate drain (outside the boiler) from the condensate trap.
3. Undo the condensate trap lock nut and remove the trap from the boiler. Disconnect the sensor leads.
4. Fit the new condensate trap and reassemble in reverse order.
5. Prime the condensate trap (fill first chamber), check for leaks.
Combustion Box
Door Panel
Burner
Fig. 56
Securing Screws
Fig. 55
Fig. 58
Heat Exchanger
Manifold
15.0
Changing Components
The burner and heat exchanger can be changed after removal of the combustion box door. To change the heat exchanger, the fan and burner must be removed first (see section 15.6 and 15.10).
1. Remove the combustion box door by removing the four securing screws (Fig. 55).
IMPORTANT: On refitting the combustion box door check the condition of the combustion box door seals.
15.10
Burner
(Fig. 56)
Support
Bracket
1. Remove the two screws securing the burner to the base of the combustion box.
Return
Connection
2. Remove the burner carefully from the combustion box base.
Fig. 57
3. Check the burner seal on the heat exchanger base, replace if necessary. Fit the new burner and reassemble in reverse order.
Flow
Switch 15.11
Heat Exchanger
1. Drain the boiler (see section 15.1 paragraph 2 & 3).
2. Remove all components in the base of the airbox.
3. Undo the screws on the support bracket. Remove the screws securing the flow switch and return connections and remove the connections (Fig. 57).
4. Remove the screws securing the heat exchanger manifold and remove the manifold (Fig. 58).
5. Lift the heat exchanger assembly (Fig. 59) and rotate the bottom upwards whilst pulling it forwards out of the airbox.
6. Fit the new heat exchanger and reassemble in reverse order.
7. Recommission the boiler and check the inhibitor concentration (see Section 6.2 and 12.1).
Heat Exchanger
Assembly
© Baxi Heating UK Ltd 2014
Fig. 59
51
Central Insulation Panel
Upper Insulation
Pad
Lower Insulation
Pad
Burner
Fig. 60
Combustion
Box Base
Support Bracket
Burner Securing
Screws
Combustion Box Base
Securing Screws
15.0
Changing Components
15.12
Heat Exchanger Lower Insulation Pad
(Fig. 60)
1. Remove all components in the base of the airbox.
2. Remove the burner (see section 15.10).
3. Remove the four bolts securing the combustion box base.
4. Remove the combustion box base.
5. Pull the central insulation panel down from the centre of the heat exchanger and remove the lower insulation pad.
6. Fit the new insulation pad and reassemble in reverse order.
15.13
Heat Exchanger Upper Insulation Pad
(Fig. 60)
1. Remove all components in the base of the airbox.
2. Remove the burner (see section 15.10).
3. Remove the heat exchanger (see section 15.11).
4. Remove the four bolts securing the combustion box base.
5. Remove the combustion box base.
6. Pull the central insulation panel down from the centre of the heat exchanger.
7. Fit the new insulation pad and reassemble in reverse order.
52
© Baxi Heating UK Ltd 2014
D
A
F
B
G
C
E
16.0
Short Parts List
Short Parts List
B
C
J
K
I
H
F
G
D
E
Key
No.
G.C.
No.
A E06 058
E06 059
E06 060
E06 085
E06 097
Description Manufacturers
Part No.
Flow Temperature
Thermistor (Red)
Flow Switch
240670
242459
Safety Thermostat
(Black) 242235
5129147 PCB
Fan 5109925
241900 Gas Valve
Viewing Window 242484
5111714 Condensate Trap
Electrodes Kit 5132097
5107430 Burner Assy
Heat Exchanger Assy 242497
I
H
K
J
© Baxi Heating UK Ltd 2014
53
Lockout
LED Light
(Red)
High
Reset
Low
ON
Boiler On
LED Light
(Green)
Mains On
LED Light
(Green)
17.0
Fault Finding
NOTE: The fan is supplied with 325 Vdc.
Fan Fault Finding should only be carried out after the boiler has been electrically isolated.
General Fault Finding should only be carried out by someone who is appropriately qualified.
Lights
Off Off Off
ON
Lights
On Off Flash
ON
YES
YES
Go to Electrical Supply section of the fault finding instructions.
Live & Neutral Reversed
Incoming Live and Neutral reversed.
Lights
On Flash Flash
ON
Lights
On Off On
ON
YES
Go to Dry-Fire section of the fault finding instructions.
YES
Go to Ignition Lockout section of the fault finding instructions.
Lights
Flash Off On
ON
Lights
Flash Flash On
ON
YES
YES
Go to Overheat Lockout section of the fault finding instructions.
Go to Fan Lockout section of the fault finding instructions.
Lights
On Flash On
ON
Lights
Flash Off Flash
ON
Lights
On On On
ON
Lights
Flash On Flash
ON
YES
YES
Go to Thermistor section of the fault finding instructions.
YES
Low Electrical Supply
Incoming Voltage less than
180V. Check System
Controls & System Wiring.
Otherwise contact Electricity
Provider.
YES
LV Wiring Harness Ensure 8way PCB connector securely pushed in. If fault persists replace LV wiring harness.
PCB Fault
Replace PCB.
Lights
On On Flash
ON
Lights
Flash On On
ON
YES
YES
PCB Fault
Replace PCB.
PCB Fault
Replace PCB.
54
© Baxi Heating UK Ltd 2014
ELECTRICAL SUPPLY
Lights
Off Off Off
ON
240V at A ?
NO
No Switched Live to boiler. Check Systems
Controls and System
Wiring.
YES
240V at B ?
NO
Check wiring from terminal block to PCB.
YES
PCB fuse OK ?
NO
Check for shorts on pump, fan & gas valve.
Replace if shorted & replace fuse.
YES
Replace PCB.
17.0
Fault Finding
A
L N Optional
Pump
Live
Fuse
B
© Baxi Heating UK Ltd 2014
55
DRY-FIRE
Lights
On Flash Flash
ON
Are
Flow & Return reversed ?
YES
Swop Flow & Return.
17.0
Fault Finding
NO
Is the system full of water ?
NO
Fill system with water and bleed out all air.
E
YES
YES
Is the pump running ?
NO
L N Optional
Pump
Live
Turn mains off & on. After 5 sec, is there 240V at E?
NO
Replace PCB.
YES
Turn mains off, unplug
7-way connector to PCB.
Is there continuity between
F and G ?
YES
Pump or Pump Wiring fault.
NO
Wiring from terminal block to PCB faulty.
Unplug
5-way PCB connector. Is there continuity between H (run pump from switched live) ?
YES
Replace PCB.
Viewed from
Wire Entry end
H
NO
Disconnect
Flow Switch Inline connector. With pump running is there continuity across flow switch ?
YES
Wires from inline connector to PCB faulty.
NO
Remove flow switch from boiler.
Is there a physical blockage to the paddle within the flow switch ?
NO
Is there a blockage in the system ?
YES
Remove Blockage.
YES
Remove Blockage.
NO
Replace Flow Switch.
7-way Connector
G
F
L N Optional
Pump
Live
56
© Baxi Heating UK Ltd 2014
IGNITION LOCKOUT
Lights
On Off On
ON
17.0
Fault Finding
I
Is there gas at gas valve inlet ?
NO
Check isolation valve and gas supply.
5-way Connector
J
YES
Reset Lockout.
Is there gas flow
(check at meter) ?
NO
YES
Is there at least
18mbar dynamic at gas valve inlet ?
NO
Remove Gas Valve & check inlet filter for blockage.
Otherwise incorrect gas supply to boiler.
YES
Is
Condensate Trap blocked or water on terminals ?
YES
Clear blockage and dry sensors.
Remove
5-way connector from gas valve. Is there 240
Vdc between I & J during ignition ?
YES
NO
Remove the larger or the two 6-way PCB connectors.
Is there continuity from I to L
& from J to K ?
YES
Replace PCB.
NO
Replace Gas Valve.
Lead from PCB to Gas
Valve faulty.
K
L
NO
Is spark or flame detection probe damaged ?
YES Replace spark or flame detection probe and gaskets.
6-way Connector
NO
Is spark gap between 3 and
4mm ?
NO
Set spark gap to 3.5mm.
YES
Is wiring from PCB to spark probe & flame detection probe OK ?
YES
NO
Rectify wiring.
Is the burner blocked or damaged ?
YES
Clean burner or replace as necessary.
NO
© Baxi Heating UK Ltd 2014
Replace PCB.
57
OVERHEAT LOCKOUT
Lights
Flash Off On
ON
Disconnect black stat on flow pipe.
When flow < 60° C is there continuity across stat ?
NO
Replace Stat.
YES
Reconnect stat.
Disconnect fan stat.
When fan temp < 60° C is there continuity across stat ?
YES
Reconnect stat.
Disconnect the larger of the 6-way PCB connectors.
Is there continuity across M ?
YES
Disconnect thermistor
(red sensor on flow pipe).
Is resistance between
0.5k
è & 20kè ?
NO
NO
NO
Replace Stat.
Wiring from PCB to thermostats faulty.
Replace thermistor.
YES
Is combustion chamber door seal damaged or not in place ?
YES
NO
Replace PCB.
Replace combustion chamber door seal & trim seal.
17.0
Fault Finding
6-way Connector
M
58
© Baxi Heating UK Ltd 2014
FAN LOCKOUT
Lights
Flash Flash On
ON
17.0
Fault Finding
NOTE: The fan is supplied with 325 Vdc.
Fan Fault Finding should only be carried out after the boiler has been electrically isolated.
Unplug
3-way PCB connector
& unplug fan. Is there continuity from N to O & from P to Q ?
NO
YES
Unplug the smaller of the
6-way PCB connector. Is there continuity from R to S & from T to U & from
V to W ?
YES
Replace fan.
NO
Rectify wiring.
Rectify wiring.
R
T
V
Fan
Connection
N
P
Fan
Connection
PCB
Connection
PCB
Connection
Viewed from
Wire Entry end
S
U
W
O
Q
© Baxi Heating UK Ltd 2014
59
THERMISTOR
Lights
On Flash On
ON
Unplug thermistor,
Is thermistor resistance between
0.5k
è & 20kè ?
NO
Replace thermistor.
YES
Plug in thermistor, leave
8-way connector unplugged.
Is resistance at D between
0.5k
è & 20kè ?
YES
Replace PCB.
NO
Wiring from PCB to thermistor faulty.
17.0
Fault Finding
Viewed from
Wire Entry end
D
60
© Baxi Heating UK Ltd 2014
18.0
Pages for Notes
© Baxi Heating UK Ltd 2014
61
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.
Customer name:
Address:
Boiler make and model:
Boiler serial number:
Commissioned by (PRINT NAME):
Company name:
Company address:
Telephone number:
Gas Safe register number:
Telephone number:
Commissioning date:
CONTROLS (tick the appropriate boxes)
Time and temperature control to heating
Time and temperature control to hot water
Heating zone valves
Hot water zone valves
Thermostatic radiator valves
Automatic bypass to system
Boiler interlock
ALL SYSTEMS
What system cleaner was used?
What inhibitor was used?
Room thermostat and programmer/timer
Load/weather compensation
Cylinder thermostat and programmer/timer
Fitted
Fitted
Fitted
Fitted
Programmable room thermostat
Optimum start control
Combination Boiler
Not required
Not required
Not required
Not required
Provided
’s instructions Yes
Quantity litres
Yes No
CENTRAL HEATING MODE measure and record:
Gas rate
Burner operating pressure (if applicable)
Central heating return temperature
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)?
m³/hr mbar
OR
OR Gas inlet pressure
Yes
Yes
DOMESTIC HOT WATER MODE Measure and Record:
Gas rate
Burner operating pressure (at maximum rate)
Cold water inlet temperature
Hot water has been checked at all outlets m³/hr OR mbar OR Gas inlet pressure at maximum rate
Yes Temperature
CONDENSING BOILERS ONLY
The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798
ALL INSTALLATIONS
Record the following:
At max. rate: CO ppm AND
At min. rate: (where possible) CO ppm AND
CO/CO² Ratio
CO/CO² Ratio
The heating and hot water system complies with the appropriate Building Regulations
The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions
The operation of the boiler and system controls have been demonstrated to and understood by the customer
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer
Commissioning Engineer’s Signature
Customer’s Signature
Yes
Yes
Yes
Yes
No
No ft³/hr mbar
°C
°C
Yes ft³/hr mbar
°C
°C
I/min
*All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer.
62
© Heating and Hotwater Industry Council (HHIC)
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.
SERVICE 01
Engineer name:
Company name:
Telephone No:
Gas safe register No:
At max. rate:
Record:
CO ppm AND
At min. rate:
(Where Possible)
CO ppm AND
Comments:
Date:
CO² %
CO² %
SERVICE 02
Engineer name:
Company name:
Telephone No:
Gas safe register No:
At max. rate:
Record:
CO ppm AND
At min. rate:
(Where Possible)
CO ppm AND
Comments:
Date:
CO² %
CO² %
Signature
SERVICE 03
Engineer name:
Company name:
Telephone No:
Gas safe register No:
At max. rate:
Record:
CO ppm AND
At min. rate:
(Where Possible)
CO ppm AND
Comments:
Date:
CO² %
CO² %
Signature
SERVICE 05
Engineer name:
Company name:
Telephone No:
Gas safe register No:
At max. rate:
Record:
CO ppm AND
At min. rate:
(Where Possible)
CO ppm AND
Comments:
Date:
CO² %
CO² %
Signature
SERVICE 04
Engineer name:
Company name:
Telephone No:
Gas safe register No:
At max. rate:
Record:
CO ppm AND
At min. rate:
(Where Possible)
CO ppm AND
Comments:
Date:
CO² %
CO² %
Signature
SERVICE 06
Engineer name:
Company name:
Telephone No:
Gas safe register No:
At max. rate:
Record:
CO ppm AND
At min. rate:
(Where Possible)
CO ppm AND
Comments:
Date:
CO² %
CO² %
Signature
SERVICE 07
Engineer name:
Company name:
Telephone No:
Gas safe register No:
At max. rate:
Record:
CO ppm AND
At min. rate:
(Where Possible)
CO ppm AND
Comments:
Date:
CO² %
CO² %
Signature
SERVICE 09
Engineer name:
Company name:
Telephone No:
Gas safe register No:
At max. rate:
Record:
CO ppm AND
At min. rate:
(Where Possible)
CO ppm AND
Comments:
Date:
CO² %
CO² %
Signature
SERVICE 08
Engineer name:
Company name:
Telephone No:
Gas safe register No:
At max. rate:
Record:
CO ppm AND
At min. rate:
(Where Possible)
CO ppm AND
Comments:
Date:
CO² %
CO² %
Signature
SERVICE 10
Engineer name:
Company name:
Telephone No:
Gas safe register No:
At max. rate:
Record:
CO ppm AND
At min. rate:
(Where Possible)
CO ppm AND
Comments:
Date:
CO² %
CO² %
Signature Signature
*All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer.
© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
63
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.
P O T T E R T O N
A T r a d i n g D i v i s i o n o f B a x i H e a t i n g U K L t d ( 3 8 7 9 1 5 6 )
Brooks House, Coventry Road, Warwick. CV34 4LL
After Sales Service 0844 871 1560 Technical Enquiries 0844 871 1555
Website www.potterton.co.uk
e&oe
© Baxi Heating UK Ltd 2014
Comp N
o
5121908 - Iss 17 - 4/14
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project