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Potthof & Co 28kw User's Manual

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1. 3 0 Appliance O peration Central Heating Mode Fig 2 1 With a demand for heating the pump circulates water through the primary circuit 2 O nce main burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor 3 W hen the flow temperature exceeds the setting temperature a 3 minute delay occurs before the burner relights automatically anti cycling The pump continues to run during this period 4 W hen the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes Pump O verrun Domestic H ot W ater Mode Fig 3 1 Priority is given to the domestic hot water supply A demand at a tap or shower will override any central heating requirement 2 The flow of water will operate the Hall Effect Sensor which requests the 3 way valve to change position This will allow the pump to circulate the primary water through the DHW plate heat exchanger 3 The burner will light automatically and the temperature of the domestic hot water is controlled by the temperature sensor 4 W hen the domestic hot water demand ceases the burner will extinguish and the diverter valve will remain in the domestic hot water mode unless there is a demand for central heating IMPORTANT W hen the selector switch is in the 0 O ff position the electrical supply to the boiler is isolated The b
2. Baxi Heating UK Ltd 2012 Flue Fig 52 10 0 Installation Fitting The Flue HORIZONTAL FLUE 1 The standard flue is suitable for lengths between 100mm minimum and 685mm maximum as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct Fig 48 2 Locate the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 50 NOTE The flue elbow is angled at 93 degrees to ensure a fall back to the boiler 3 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 51 4 To dimension X add 50mm This dimension to be known as Y IMPO RTANT Check all dimensions before cutting 5 Mark dimension Y on the flue as shown Fig 52 Carefully cut the waste material from the flue ensuring that the ducts are square and free from burrs 33 Inner Flue Support Bracket Apply Lubricant for ease of assembly Ensure Flue is fully engaged into Flue Elbow Slots at bottom Fig 55 Fig 54 Extension ie Fig 56 Cut End lt Tape Adaptor Apply Lubricant for ease of assembly Ensure Extension is fully engaged into Boiler Adaptor Fig 57 34 Baxi Heating UK Ltd 2012 10 0 Installation Fitting the Flue C ont 6 The inner flue duct support bracket may be in the waste portion of the flue In this
3. 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 Telephone Number Address Boiler Make and Model Bo er SerialNumber ESA E C PITTETT PTET Tt ttt Ett tt tee et et S Commissioned by print name Gas Safe Register Number Company Name Telephone Number Company Address Commissioning Date To be completed by the customer on receipt of a Buildings Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather Optimum Start Programmer Timer Room Thermostat Compensation Control Time and T
4. Above ground roof or balcony level 300 From a surface or boundary line facing a terminal 600 1 The following guidelines indicate the general requirements K From a terminal facing a terminal Horizontal flue 1200 for siting balanced flue terminals For GB recommendations are From a terminal facing a terminal Vertical flue 600 given in BS 5440 Pt 1 For IE recommendations are given in L From an opening in carport e g door window the current edition of S 813 Domestic Gas Installations into the dwelling 1200 Vertically from a terminal on the same wall 1500 2 If the terminal discharges onto a pathway or passageway N OREO Many Troni a terminai oni tne amean ae check that combustion products will not cause a nuisance and R From adjacent wall to flue vertical only 300 f S From an adjacent opening window vertical only 1000 that the terminal will not obstruct the passageway T Adjacent to windows or openings on pitched and flat roofs 600 a U Below windows or openings on pitched roofs 2000 3 If a terminal is less than 2 metres above a balcony above ground or above a flat roof to which people have access then 1 In addition the terminal should be no nearer than 150 mm to an opening in the a suitable terminal guard must be provided building fabric formed for the purpose of accommodating a built in element such as a window frame 4 This dimension may be reduced to 25mm by the use of 20 nly ONE 25mm clearance is allowed p
5. Case Front Panel a 2 Set the central heating and hot water temperature control knobs to the requirements of the user 3 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist 5 Hand over the Users O perating and Installation and Servicing Instructions giving advice on the necessity of regular servicing Facia Panel Fig 72 Baxi Heating UK Ltd 2012 39 RE Front Panel SS Fig 73 Facia Panel Securing Screws Inner Door Panel Fig 14 Fig 75 40 Baxi Heating UK Ltd 2012 13 0 Servicing 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 Interva
6. 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 D esigns 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 H eating UK Ltd Brooks House Coventry Road W arwick CV34 4LL Full acknowledgement of author and source must be given W ARN ING Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages Certification Mark 2 Baxi Heating UK Ltd 2012 Building Regulations and the Benchmark Commissioning Checklist Building Regulations England amp W ales 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 amp Safety Executive operates the Gas Safe Register a self certification scheme for gas heating appliances These arrangements represent a change from the situation whereby compli
7. 2 0 General Layout 8 Hi 3 0 Appliance O peration 9 4 0 Technical Data 10 5 0 Dimensions and Fixings 11 6 0 System Details 12 7 0 Site Requirements 15 8 0 Flue Options 19 9 0 Plume Displacement 24 10 0 Installation 28 11 0 Commissioning 34 12 0 Completion 37 13 0 Servicing 38 14 0 Changing Components 40 15 0 Setting the Gas Valve 49 160 Electrical 50 17 0 Short Parts List 51 18 0 Fault Finding 52 Benchmark Checklist 58 Baxi Heating UK Ltd 2012 Lower Door Panel Fig 1 Baxi Heating UK Ltd 2012 Case Front Panel Data Badge Information Label 1 0 Introduction Description 1 The Potterton Gold Combi HE a is a fully automatic gas fired wall mounted condensing combination boiler It is room sealed and fan assisted and will serve central heating and mains fed domestic hot water 2 The boiler is set to give a maximum output of 24 models 24 kW DHW 21 kW CH Condensing 28 models 28kW DHW 25 9 kW CH Condensing 33 models 33 kW DHW 30 3 kW CH Condensing 3 It is designed for use on N atural Gas G20 4 The boiler is suitable for use only on fully pumped sealed heating systems Priority is given to domestic hot water 5 The boiler is supplied with a filling loop and integral timer 6 The boiler data badge gives details of the model serial number and Gas Council number and is situated on the inner door panel It is visible when the case front p
8. 45 5106164 FLUEGROUPG Concentric Flue System 80 125mm diameter A4 Horizontal Flue Kit 5118580 B Straight Extension Kit 1000mm 5118584 D Bend Kit pair 135 5118597 C Bend 915 5118588 U Pipe support 125mm 5118610 FLUEGROUPA N G Vertical Flue Kits K Vertical Flue Terminal use with 5111070 5111078 K1 Vertical Flue Terminal 5118576 L Pitched Roof Flashing 25 50 5122151 M Roof cover plate 246143 N Flat roof flashing 246144 24 Baxi Heating UK Ltd 2012 Air Duct Connection Flue Duct Connection Boiler Adaptor 8 0 Flue Options EE Twin Flue Duct Adaptor 1 The kit allows connection of a twin flue system to the boiler adaptor Twin Flue Connection 1 Engage the twin flue duct adaptor in the boiler adaptor making sure that it is pushed down as far as possible 2 Ensure that the air amp flue ducts are connected correctly and that they are adequately supported at least once every metre using the available pipe supports 3 Ensure that all joints and elbows are fully engaged and cannot become disconnected during operation amount off the Air Duct amp Flue Duct Cut the same Approx 1425mm Baxi Heating UK Ltd 2012 8 0 Flue Options ECM For Roof Terminals 1 In the case of a pitched roof 25 50 de
9. Remove the sensor examine the sealing washer replacing if necessary 5 Reassemble in reverse order The component is not polarised either wire will fit each terminal ISON Central Heating Temperature Sensor NTC Fig 88 1 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way aie Safety Thermostat Fig 88 1 Pull the plug off the thermostat 2 Remove the screws securing the thermostat to the mounting plate on the flow pipe 3 Reassemble in reverse order ensuring that the plug is pushed fully on EP DHW Temperature Sensor NTC Fig 89 1 Turn off the mains cold water supply tap and draw off the residual domestic hot water 2 Ease the retaining tab on the sensor away and disconnect the electrical plug 3 Unscrew the sensor from the plate heat exchanger manifold Examine the sealing washer replacing if necessary 4 Reassemble in reverse order The plug will only fit one way 45 Pump W iring Cover Socket H eaded Screw Pump Setting Fig 92 Pump W iring Cover 46 Baxi Heating UK Ltd 2012 Pump H ead Automatic Air Vent Fig 91 Fig 93 14 0 Changing Components Pump Head O nly Fig 91 1 Drain the boiler primary circuit and remove the socket head screws securing
10. each 45 bend to 0 5 metres Flue Length W orked Example Potterton Gold Combi 33HE a In Fig 27 opposite an additional 93 bend and pair of 45 elbows have been included in the 609 exhaust Also 3 straight extension pieces have been used To calculate total length Length of 609 supplied in kit 1 metre 3 x 1 metre Extensions 3 metres 1 x 93 Elbow 1 metre 2 x 45 Elbow 1 metre 0 5 metres each Total 609 6 metres After consulting the table in Example 3 it can be determined that the concentric flue could be up to approximately 2 3 metres long 27 00 1 000 Min 2 metres Fig 28 Flue Trim Spigot Position of Jubilee Clip Fig 29 t screw 50mm lt lt er Adaptor Fig 31 wo one Fig 30 28 Baxi Heating UK Ltd 2012 Fig 33 9 0 Plume Displacement General Fitting Notes 1 Cut a hole in the external wall which the concentric flue assembly will pass through The hole should allow the flue to fall back to the boiler at an angle of at least 1 5 2 W hen completed the terminal must be at least 2 metres above ground level Fig 19 3 Measure and cut to size the concentric assembly and any extensions that are being used 4 Insert the concentric assembly thr
11. using the plug and screw provided 13 Mark and drill the 60 exhaust using a 2mm bit as shown in Fig 23 Complete the installation of the 600 exhaust securing in the brackets 14 Fit the 93 elbow plume outlet and secure with the two remaining screws supplied Ensure the plume outlet is at least 45 to the wall and that the peak is uppermost Fig 24 Plume O utlet Elbow Fig 36 200mm Min Fig 37 Outlet Spigot Baxi Heating UK Ltd 2012 9 0 Plume Displacement General Fitting N otes cont 15 For aesthetic purposes it is permissible to route the 609 exhaust in an enclosed box but the air inlet and plume outlet MUST remain in free air 16 It is also possible to separate the plume outlet from the 93 elbow to allow the flue to be installed as shown in Fig 34 17 To do this first slacken the two screws retaining the plume outlet to the elbow and remove the outlet Fig 35 The elbow can now be used to connect the vertical to horizontal 609 exhaust Fig 34 Retighten the screws in the elbow 18 The outlet can now be fitted into the female end of an 609 extension piece It must be secured using two of the screws supplied in the bag with the Jubilee clip 19 Mark the female end of the extension at 30mm as shown in two positions directly opposite each other Fig 36 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure
12. Ensure that the filling loop is connected and open then open the heating flow and return valves on the boiler 6 O pen the screw on the automatic air vent on the pump body Fig 63 7 The system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 8 Pressurise the system to 1 5 bar Fig 64 then close and disconnect the filling loop Fig 63 9 Turn the gas supply on and purge according to in GB BS 6891 and in IE 1S 813 Domestic Gas Installations Selector Switch Fig 64 Pressure Gauge 10 Test for gas tightness Display 11 Hinge the facia panel upwards and refit the case front panel Tighten the securing screws IMPO RTANT The combustion for this appliance has been checked adjusted and preset at the factory for Y me Te z 4 operation on the gas type specified on the appliance data s plate No measurement of the combustion is necessary i Do not adjust the air gas ratio valve Central H eating Domestic H ot W ater Temperature Control Temperature Control 12 Having checked Fig 65 That the boiler has been installed in accordance with these instructions e The integrity of the flue system and the flue seals e The integrity of the boiler combustion circuit and the relevant seals Proceed to put the boiler into operation as follows 36 Baxi Heating UK Ltd 2012 X Central H eating Domestic Hot W ater Temp
13. Sensor 5 Cold W ater Inlet Tap Blanking Cap Restricter vs Fes N A Hydraulic Inlet D ENE Assembly 7 GE Lx Fig 79 Filter Baxi Heating UK Ltd 2012 13 0 Servicing Annual Servicing Inspection C ont 6 Undo the nut on the gas inlet pipe to the venturi Fig 77 and pull the sensing pipe off the fan 7 Disconnect the electrode leads noting their position and the fan electrical plugs 8 Undo the four nuts retaining the combustion box cover to the heat exchanger 9 Carefully draw the fan collector and cover assembly forward being careful to retain the injector in the venturi Figs 76 amp 77 10 Clean any debris from the heat exchanger and check that the gaps between the tubes are clear 11 Inspect the burner electrodes and insulation cleaning or replacing if necessary Clean any dirt or dust from the air box 12 Reassemble in reverse order N OTE The sensing pipe must be reconnected to the fan not the venturi DHW Filter Fig 79 13 If the flow of domestic hot water is diminished it may be necessary to clean the filter 14 Initially check the cold water inlet tap filter 15 Turn the tap off and draw off from a hot tap Undo the blanking cap and remove the threaded bush Fig 78 16 Extract the filter and rinse thoroughly in clean water Reassemble and check the flow If required clean the restricter filter as described below 17 Pull off the
14. case retrieve the bracket before discarding the waste 7 Take the inner flue support bracket if not already fitted and engage it over the flue duct This will centralise the flue and air ducts and ease assembly Fig 53 8 Insert the flue through the hole in the wall Fit the elbow to the boiler adaptor ensuring that it is pushed fully in 9 Draw the flue back through the wall and engage it in the elbow It may be necessary to use soap solution or similar to ease assembly of the elbow adaptor and flue Fig 54 10 Ensure that the terminal is positioned with the slots to the bottom Fig 55 IMPO RTANT It is essential that the flue terminal is fitted as shown to ensure correct boiler operation and prevent water entering the flue 11 Make good between the wall and air duct outside the building 12 Fit the flue trim if required and if necessary fit a terminal guard see Section 8 8 amp 8 9 CONCENTRIC VERTICAL FLUE 13 Once the length of the vertical concentric extension has been determined mark and carefully cut off the excess material The cut end MUST be square and free of burrs to ensure correct insertion into the boiler adaptor 14 Measure 25mm from the end of the flue extension and apply a length of tape around the outer duct Fig 56 15 Engage the extension into the adaptor up to this position Fig 57 O nce the installation of the flue is complete and all support brackets are securely in pl
15. circuit and undo the nut on the vessel connection pipe Fig 103a 2 Undo and remove the locknut securing the vessel spigot to the boiler air box 3 Remove the bracket and vessel from the boiler 4 Locate the retaining bracket on the upper flange of the Expansion Vessel vessel and fit to the boiler 5 Reassemble in reverse order Boiler Chassis Fig 104 50 Baxi Heating UK Ltd 2012 IMPORTANT The CO2 must be only be checked and adjusted to set the valve if a suitable calibrated X 2 15 0 Setting the Gas Valve w z Setting the Gas Valve C O2 check combustion analyser is available operated by a competent person see Section 13 1 Central H eating Domestic H ot W ater Temperature Control Fig 105 Temperature Control 1 The combustion CO 2 may be checked after running the Selector Switch Display boiler for several minutes To do this it is necessary to set y the boiler to Calibration Mode mE T EM Central H eating D omestic Hot W ater Temperature Control Temperature Control n O O 2 Ensure that all external controls are calling for heat The actual current boiler temperature is shown on the display 4 X 3 Turn both control knobs fully anticlockwise then quickly turn the right hand knob s clockwise twice and back fully anticlockwise Fig 105 4 The display will now alternate between SF and the current
16. competence A person who works for a Gas Safe registered company and holding current certificates in the relevant ACS modules is deemed competent In IE this must be carried out by a competent person as stated in I S 813 Domestic Gas Installations The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty In GB this could also infringe the Gas Safety Installation and Use Regulations W arning Check the information on the data plate is compatible with local supply conditions All Gas Safe registered engineers carry an ID card with their licence number and a photograph You can check your engineer is registered by telephoning 0800 408 5500 or online at www gassaferegister co uk The boiler meets the requirements of Statutory Instrument The Boiler Efficiency Regulations 1993 N 3083 and is deemed to meet the requirements of Directive 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purpose of Regulation 5 certified by Notified Body 0085 Product Production certified by N otified Body 0086 For GB IE only Baxi Heating UK Ltd 2012 Legislation This company declare that no substances harmful to health are contained in the appliance or used during appliance manufacture The appliance is
17. connector is 230V AC across Fan jammed or faulty winding Replace fan terminals 5 amp 7 Replace PCB Baxi Heating UK Ltd 2012 57 18 0 Fault Finding E E20 or E50 Temperature sensors faulty Cold resistance approximately 10kQ 25 C DHW and CH sensors 20kQ 25 C Flue sensor Replace sensor or PCB E28 resistance reduces with increase in temp E28 Incorrect PCB fitted Check and correct the connection of the tube between the venturi and gas valve 2 Ensure gas is on and purged PCB X3 connector is 230V AC across terminals 1 amp 2 NO Replace PCB Replace gas valve Ensure that the Hall Effect Sensor is in position YES Check the voltage between red wire and blue Check the connection between the PCB X 400 connector terminals 3 6 7 and the electronic sensor wire is more than 5V DC TS Replace PCB Replace H all Effect Sensor l Voltage at PCB X2 connector is at H C n r and correct iinecessary least 100V DC across terminals 2 amp 5 Replace PCB 1 Ignition electrode and lead l 9 N ote from multimeter connect 2 Electrode connection ommon to 2 amp volke to 5 ENA 3 Spark gap and position A eplace igniter eal aa Check wiring DD i 1 4405 Burner l Ta F t Sensing Electrode Spark Ignition Electrode Electrode Position 58 Baxi Heating UK Ltd 2012 K 18 0 Fault Finding 1 Check that the supply pressure at the te
18. length is 10 metres 60 100 system 20 metres 80 125 system Flue Trim 1 The rubber flue trim supplied may be fitted to either the outside wall or on the inner wall of installation ECM Terminal Guard Fig 21 1 W hen codes of practice dictate the use of terminal guards they can be obtained from most Plumbers and Builders Merchants 2 There must be a clearance of at least 50mm between any part of the terminal and the guard 3 W hen ordering a terminal guard quote the appliance name and model number 4 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated Flue Deflector Fig 20 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 25 93 Elbow Plume O utlet Assembly 609 Support O Ring Sd Bracket ra j 608 Exhaust ce Flue Pipe 609 Support p Bracket i O Rin ia coe U Flexible Flue a5 Trim Adaptor CO x g Jubilee Clip O Ring neee gt O 60 1008 Concentric Flue Outlet must be at least 45 from Peak Uppermost wall face 500mm Min Air Inlet at Bottom 000 000 Fig 25 26 Baxi Heating UK Ltd 2012 9 0 Plume Displacement Plume Displacement Kit Fig 23 Kit No 5118638 Content of kit 1 0 9m 60 100 Concentric Flu
19. pressure The pressure reduction must take account of all fittings connected to the DHW system CM Showers 1 If a shower control is supplied from the appliance it should be of the thermostatic or pressure balanced type Thermostatic type shower valves provide the best comfort and guard against water at too high a temperature Existing controls may not be suitable refer to the shower valve manufacturer Hard W ater Areas 1 If the area of the installation is recognised as a HARD W ATER AREA then a suitable device should be fitted to treat the mains water supply to the boiler Contact your W ater Distribution Company for advice on suitable devices 7 0 Site Requirements 5mm Min 450mm 5mm Min QI Location 200mm Min 1 The boiler may be fitted to any suitable wall with the flue 300mm Min if passing through an outside wall or roof and discharging to using 80 125mm atmosphere in a position permitting satisfactory removal of fiueing system combustion products and providing an adequate air supply The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i e garage or outhouse The boiler may be fitted inside a cupboard see Section 7 3 2 If the boiler is sited in an unheated enclosure then it is recommended to leave the O N O FF Selector Switch in the domestic hot water and central heating position to give frost protection 780mm 3 If the bo
20. the concentric flue assembly and any extensions and the 60 exhaust and any extensions or additional bends Example 1 N ot Permissible If for instance a concentric length of 5 metres was required and the 60 exhaust needed to be 6 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 W here 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 60 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 in Fig 4 assume that the concentric part of the flue needs to be 2 3 metres long Find the position of 2 3 on the horizontal axis of the graph and then project upwards to the solid diagonal line This is represented by the vertical thick dotted line W here this dotted line intersects with the solid diagonal line on the graph project across to the vertical axis As can be seen this corresponds with 6 metres Therefore the total equivalent length of the 609 exhaust can be up to 6 metres Any bend equivalencies must be accounted for i e 93 bends are equal to 1 metre
21. the pump head to the body and draw the head away 2 Undo the screw on the pump wiring cover and remove the cover U sing a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 3 A standard replacement Grundfos 15 60 head can now be fitted Connect the pump wiring to the new head The pump speed must be set to 3 Fig 92 4 Reassemble in reverse order IARE Pump Complete Fig 93 1 Drain the boiler primary circuit 2 Undo the two screws securing the body to the pipe and manifold and draw the pump forwards 3 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 4 Unscrew the automatic air vent from the pump body 5 Connect the wiring to the new pump Examine the 0 ring seals on the return pipe and manifold replacing if necessary 6 Fit the air vent to the pump body and reassemble in reverse order BK Automatic Air Vent Fig 93 1 Drain the boiler primary circuit and unscrew the automatic air vent from the pump body 2 Examine the O ring seal replacing if necessary and fit it to the new automatic air vent 3 Reassemble in reverse order 14 0 Changing Components Gauge Retaining WM Pressure Gauge Figs 94 amp 95 Bracket 1 Drain the boiler primary circu
22. to 0 5 bar minimum when the boiler is cold 4 The preferred minimum gas pressure is 20 mbar 5 Carry out electrical system checks i e Earth Continuity Resistance to Earth Short Circuit and Polarity with a suitable meter NOTE These checks must be repeated after any servicing or fault finding 6 Ensure all external controls are calling for heat and check all external and internal fuses Before any servicing or replacement of parts ensure the gas and electrical supplies are isolated Error Codes 1 If a fault occurs on the boiler an error code may be shown by the facia display 2 The codes are either two or three digit preceded by the letter E For example code E133 will be displayed by E1 alternating with 33 E50 is shown as E then 50 E20 E28 amp E50 indicate faulty or incorrect components E110 shows overheat of the primary water and E130 overheat of the flue system E119 is displayed when the primary water pressure is less than 0 5 bar E133 indicates that the gas supply has been interrupted ignition has failed or the flame has not been detected E125 is displayed in either of two situations i If within 15 seconds of the burner lighting the boiler temperature has not changed by 1 ii If within 10 minutes of the burner lighting the boiler temperature twice exceeds the selected temperature by 30 In these instances poor primary circulation is indicated 3 By turning the selector sw
23. to 125 litres 24 28 models 155 litres 33 models For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt 1 For IE the current edition of I S 813 Domestic Gas Installations Safety Pressure Relief Valve Fig 6 1 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable for pressures in excess of 3 bar and temperature in excess of 100 C 2 The pressure relief discharge pipe should be not less than 15mm dia run continuously downward and discharge outside the building preferably over a drain It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components The end of the pipe should terminate facing down and towards the wall 3 The discharge must not be above a window entrance or other public access Consideration must be given to the possibility that boiling water steam could discharge from the pipe 4 A remote relief valve kit is available to enable the boiler to be installed in cellars or similar locations below outside ground level kit no 5121379 13 Other Tap Outlets Expansion Vessel See 6 8 for instances when these items may be required Fig 7 14 Baxi Heating UK Ltd 2012 6 0 System Details 68 Domestic Hot W ater Circuit Fig 7 1 All DHW circuits connections fittings etc should be fully in accordance with releva
24. using two of the screws supplied 21 The remaining screw must be used to secure the adaptor to the concentric terminal 22 W hen the plume outlet is positioned under a balcony or other projection Fig 37 it must protrude at least 200mm it is not necessary to extend it further than this 23 W hen under balconies or projections it is permissible to rotate the concentric flue length up to 70 clockwise or anti clockwise Fig 38 if there is insufficient space to connect vertically 24 This will allow the connection of the exhaust to the outlet spigot 25 All other minimum amp maximum dimensions must be adhered to and the air inlet positioned such that it will not be subject to rain entry Concentric Flue Length shown end on Fig 38 m Fig 39 For Side Flue Exit Fig 41 Flushing Tube Central H eating Return Fig 42 30 Baxi Heating UK Ltd 2012 10 0 Installation Unpacking amp Initial Preparation The gas supply gas type and pressure must be checked for suitability before connection see Section 7 4 NOTE a small amount of water may drain from the boiler in the upright position 1 Remove staples open flaps and remove the cardboard sheet Remove the polystyrene side pieces and literature Two people can then lift out the boiler Figs 39 amp 40 2 After considering the site requirements see Section 7 0 position the fixing template on the w
25. 664201 5 metre 720664401 W here the drain is between 3 amp 5 metres a5 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 H eating Element is NOT a substitute for correct installation of the condensate drain ALL requirements in this section must still be adhered to vii to a drain or gully with extended external run amp trace heating The Trace Heating element must be installed in accordance with the instructions supplied External runs amp those in unheated locations still require insulation Boiler Pipe must terminate above water level but below surrounding surface Cut end at 45 19 Terminal Position with Minimum Distance Fig 18 7 0 Site Requirements Al Directly below an opening air brick opening windows etc 300 Bl Above an opening air brick opening window etc 300 C1 Horizontally to an opening air brick opening window etc 300 Flue D2 Below gutters soil pipes or drain pipes 25 75 see ae 25 200 NOTE Due to the nature of the boiler a plume of water elow balconies or car port roof 25 200 f f G2 From a vertical drain pipe or soil pipe 25 150 vapour will be discharged from the flue This should be H2 From an internal or external corner 25 300 taken into account when siting the flue terminal
26. 81 1 Disconnect the electrode leads noting their positions 2 Remove the retaining screws securing each of the electrodes to the combustion box cover and remove the electrodes 3 Check the condition of the sealing gasket and replace if necessary Reassemble in reverse order Venturi Injector Burner Fe 1 Gas Inlet Fan Venturi Injector Collector Fig 82 Fig 84 W hen fitting the venturi ensure that the arrow is pointing forward Baxi Heating UK Ltd 2012 14 0 Changing Components Fan Fig 83 1 Undo the nut on the gas inlet pipe to the venturi Fig 83 and pull the sensing pipe off the fan 2 Disconnect the electrode leads noting their position and disconnect the fan electrical plugs 3 Undo the screws securing the collector to the cover 33 models or extension piece 24 amp 28 models 4 Remove the collector and fan assembly being careful to retain the injector in the venturi 5 Undo the screws securing the fan to the venturi and fit the new fan replacing the seal if necessary 6 Examine the burner gasket and replace if necessary 7 Reassemble in reverse order ensuring that the injector is in place and the sensing pipe is connected to the fan Venturi Fig 82 1 Remove the collector and fan assembly as described in section 14 3 2 Extract the injector from the venturi 3 Undo the screws securin
27. C to the new valve and reassemble in reverse order Control Box Cover Fig 101 P C B Selector Switch p rg Drive Pins mA at Facia Fig 102 Baxi Heating UK Ltd 2012 14 0 Changing Components MEA P C B Fig 102 1 N ote the settings of the temperature control knobs rotate them fully anticlockwise and carefully pull them off the drive pins 2 Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hinge pin Fig 101 3 Note the position of all plugs and wires on the P C B and disconnect them 4 Undo the securing screws and remove the P C B Transfer the control knob drive pins to the new P C B and turn them fully anticlockwise 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions Wem Selector Switch Fig 102 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hinge pin Fig 101 3 Note the position of the electrical connections and the orientation of the switch Remove the electrical connections 4 Remove the screws securing the switch to th
28. Hall Effect sensor Undo the restricter from the inlet return manifold Fig 79 18 Rinse the filter thoroughly in clean water and reassemble in reverse order 19 Turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler 20 Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user 41 Bracket _ Igniter Igniter Feed Plug Electrode s Leads Fig 80 Spark Electrode Electrod Leads Sensing Electrode Fig 81 42 Baxi Heating UK Ltd 2012 14 0 Changing Components IMPO RTANT W hen changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started W hen the component has been changed turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler before recommissioning See Section 13 2 Annual Servicing for removal of case panel door etc Igniter Fig 80 1 Disconnect the igniter feed plug and the electrode leads noting their positions 2 Undo the screw securing the bracket to the boiler 3 Remove the igniter and transfer the bracket to the new component 4 Reassemble in reverse order Spark and Sensing Electrodes Fig
29. You can rely on POTTESJON Installation amp Service Instructions Gold HE a Range Condensing Combination Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Baxi Heating UK Ltd 2012 Natural Gas Potterton Gold Combi 24 HEA G C N 47 393 18 Potterton Gold Combi 28 HEA G C N 47 393 19 Potterton Gold Combi 33 HEA G C N 47 393 20 The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information Baxi Heating UK Ltd 2012 All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means or stored in any retrieval system of any nature including in any database
30. ace remove the tape Terminal Block Cover Q INN V ne Cable Clamp Facia Panel Fused Spur L N Room Stat bk JOES bk 2 JOL_ sy JOC QC Her br Fig 60 Frost Thermostat Fused Spur L N DA M Room Stat 230V bk bk 2 External Clock gly b br Fig 61 NOTE The 230V switched signal for external controls Frost Stat Room Stat Timer must always be taken from terminal 2 at the boiler Live N eutral and Earth to power these controls must be taken from the Fused Spur Baxi Heating UK Ltd 2012 10 0 Installation Making The Electrical Connections NOTE Both the Live and N eutral connections are fused To connect an external control proceed as follows 1 Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia Remove the panel 2 Completely undo the screws securing the facia panel and hinge it down Fig 58 3 Undo the terminal block cover securing screw and remove the cover Fig 58 4 Slacken the unused cable clamp on the LH side of the boiler chassis Fig 59 Insert the external control wiring through the clamp and route it to the terminal block 5 Refer to the instructions supplied with the control IMPORTANT The room thermostat MUST be suitable for 230V switching NOTE An external frost thermostat cannot be us
31. al Gas G20 After 10 mins 24 model m h 28 model mh 33 model m h NOTE All data in this section are nominal values and subject to normal production tolerances 2 61 31 3 6 SEDBUK Declaration The efficiency is 91 1 all models 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 Baxi Heating UK Ltd 2012 4 0 Technical Data Gold Combi 24 28 amp 33 HEa Inlet Pressure N atural Gas G20 mbar 20 Injector Natural Gas G20 7 5mm 24 amp 28 model 12mm 33 model Electrical Supply 230V 50H Appliance must be connected to an earthed supply Power Consumption 155W 24 amp 28 model Electrical Protection 160W 33 model IPX OD External Fuse Rating 3A Internal Fuse Rating F2L Condensate Drain To accept 21 5mm in plastic waste pipe Flue Terminal Diameter 100mm Dimensions Projection 125mm Connections copper tails Gas Supply 22mm Central H eating Flow 22mm Central H eating Return 22mm Cold W ater Mains Inlet 15mm DHW Flow 15mm Pressure Relief Discharge 15mm O utercase Dimensions Casing H eight 780mm O verall H eight Inc Flue Elbow 965mm Casing W idth 450mm Casing Depth 345mm Clearances Above Casing 200 mm Min Below Casing 150 mm Min Front 450 mm Min For Servicin
32. all ensuring it is level both horizontally and vertically 3 Mark the position of the two most suitable fixing slots for the wall plate and boiler lower fixing holes It is preferable to use the vertical fixing slots 4 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 41 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 116mm 7 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using the fixing screws 8 Using a spirit level ensure that the plate is level before finally tightening the screws 9 Connect the gas and water pipes to the valves on the wall plate using the copper tails supplied Ensure that the sealing washers are fitted between the connections 10 Fit the filling loop as described in the instructions supplied with it Flushing 1 Connect a tube to the central heating flow or return pipe Fig 42 amp 43 2 Flush thoroughly see System Details Section 6 2 N ote Full instructions are provided in the Filling Loop Kit pack Cold Inlet Blanking C aps ex CH Return Pressure Gauge Blanking Plugs Hose and Fitting Fig 44b Baxi Heating UK Ltd 2012 10 0 Installation Fitting the Filling Loop Kit 1 The filling loop kit supplied with the boiler can be connected to the
33. ance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook which was then left on site with the customer W ith 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 benchmar COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS BSI ISO 9001 FM 00866 TM Installer Notification Guidelines Choose Building Regulations No
34. and Fixings Dimensions 780mm At least 1 5 345mm 450mm 116mm Min 185mm 207mm for 80 125mm flue systems 145mm 131mm 180mm 270mm Flue 100mm Tap Rail 2 5 mm A Condensate Drain 65 mm 65 mm 65 mm 65 mm 65 mm rea Heating Domestic Hot Gas Cold Water Heating Pressure Relief Flow Water Outlet Inlet Inlet Return Valve 22mm 15mm 22mm 15mm 22mm 15mm bm 4 G fta m P4 Baxi Heating UK Ltd 2012 11 12 Baxi Heating UK Ltd 2012 6 0 System Details Information 1 The Potterton Gold Combi HE a Condensing C ombination Boiler isa Water Byelaws Scheme Approved Product To comply with the W ater Byelaws your attention is drawn to the following installation requirements and notes IRN a IRN 001 See text of entry for installation requirements and notes b IRN 302 Byelaw 14 2 Reference to the W Rc publications W ater fittings and materials directory and W ater supply byelaws guide give full details of byelaws and the IRN s Central Heating Circuit 1 The appliance is suitable for fully pumped SEALED SYSTEMS ONLY Treatment of W ater Circulating Systems 1 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 sys
35. anel is removed Fig 1 7 The boiler model name and serial number are also shown on the information label on the rear or the lower door panel This is for user reference 8 The boiler is intended to be installed in residential commercial light industrial EM C environments on a governed meter supply only 9 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit part no 5118489 9 All systems must be thoroughly flushed and treated with inhibitor see section 6 2 Contents of Pack 1 Boiler Unit 2 W all Plate inc taps 3 Set of Pipes inc nuts 4 Template amp Q uick Fit Guide 5 Timer Blanking Plate Kit 6 Literature Pack 7 Filling Loop 8 Baxi Heating UK Ltd 2012 2 0 General Layout o nm nn RF W ND N N N N NY ON N NY ON KB RP RP PP PP PP PP PP HBH er Aa KR ON S nu AAR WN ES Layout Expansion Vessel Automatic Air Vent DHW Plate Heat Exchanger Automatic Bypass Circulation Pump Drain O ff Point Safety Pressure Relief Valve O ptional Integral Timer Position Central Heating System Pressure Gauge PCB Control Box 3 W ay Valve Assembly Condensate Trap Flame Sensing Electrode Spark Electrode Primary H eat Exchanger Fan Assembly O n O ff Reset Selector Switch Central Heating Temperature Control Ho
36. ation of the boiler DHW Temporary CH Mains Hose Return Inlet Fig 4 Filling Loop Fig 5 Fig 6 Pressure Relief Valve Discharge Pipe Baxi Heating UK Ltd 2012 6 0 System Details System Filling and Pressurising Fig 4 1 A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement refilling A filling loop amp instructions are provided with the boiler 2 The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment 3 Your attention is drawn to for GB Guidance G24 2 and recommendation R24 2 of the W ater Regulations Guide for IE the current edition of S 813 Domestic Gas Installations 4 The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe provided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use CM Expansion Vessel Central H eating only 1 The appliance expansion vessel is pre charged to 0 5 bar Therefore the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up
37. ay 3 Remove the cover insulation piece 4 Fit the new insulation carefully over the burner and align it with the slots for the electrodes 5 If the rear insulation requires replacement remove it and all debris from the heat exchanger Also it may be necessary to separately remove the spring clip from the pin in the centre of the heat exchanger and the L shaped clips embedded in the insulation 6 DO NOT remove the shrink wrapped coating from the replacement rear insulation Keep the insulation vertical and press firmly into position 7 Examine the cover seal and replace if necessary Electrical Flue H eat Exchanger Thermostat Sensor Fig 87 Flow Pipe Central H eating Temperature 21 IA 07 Safety Thermostat Fig 88 Pressure Sensor Plate Heat Exchanger Fig 89 DHW Temperature Sensor Baxi Heating UK Ltd 2012 14 0 Changing Components Flue H eat Exchanger Thermostat Sensor Fig 87 1 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Turn the sensor 90 anticlockwise to remove it is a bayonet connection 3 Reassemble in reverse order W ater Pressure Sensor Fig 89 1 Drain the primary circuit 2 Disconnect the two wires from the sensor 3 Undo the nut on the flow pipe securing and sealing the sensor 4
38. boiler temperature and both green LEDs will flash Figs 106 amp 107 5 Turn the left hand knob fully clockwise As the knob is turned the display will change indicating the fan speed 6 The display will show 00 indicating maximum rate then revert to P alternating with the current boiler temperature Figs 108 109 amp 110 7 Remove the plug from the flue sampling test point Insert the analyser probe and allow sufficient time for the reading to settle Fig 111 iar Lou ae The CO should be 8 7 0 2 Flue Adaptor Test 8 It is possible to alter the CO 2 by adjustment of the gas Pont valve Remove the plastic cover from the Throttle Plug ee e Adjustment Screw At maximum rate the Throttle LL LA Adjustment Screw should be turned using a suitable Analyser Probe __ ce hexagon key until the correct reading is obtained Fig 112 de AP Turning clockwise will reduce the CO 2 Anticlockwise will increase the CO 2 O fiset 9 The CO 2 must then be checked at minimum rate Turn Adjustment Screw the left hand knob fully anti clockwise As the knob is turned cap fitted Throttle the display will change indicating the fan speed W hen the Adjustment Screw display reads 0 the boiler runs at minimum rate cover removed The CO should be 8 4 0 2 MO Reduce CO2 Increase CO2 at min rate at min rate a 10 W ith the boiler on minimum the O ffset Adjustment Screw must be altered usi
39. e 1m 60 Dia Exhaust Flue Pipe Adaptor 60 Dia Support Brackets 93 Elbow Plume O utlet Assembly Flexible Flue Trim O Rings Jubilee Clip Boiler Elbow BRUNE 1 This kit is recommended for installations where the condensate plume emitted from the flue may cause a nuisance or affect the surroundings 2 The terminal must be positioned outside the building with the air inlet facing downward and outlet connection upwards 3 The plume outlet must always be at least 45 to the wall with the peak uppermost to prevent rain entry Figs 24 amp 25 and be at least 2 metres above ground level It must be secured as shown in Fig 19 The plume outlet must also be at least 500mm from the air inlet in any direction Fig 25 NOTE The outlet must be positioned so that any condensate plume is directed away from adjacent surfaces There must be a constant fall along the entire length of the flue system from the outlet back to the boiler 4 It is possible to reduce or increase with the addition of extensions the length of either or both the 60 100 concentric and 60 exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length of the concentric flue is 100mm when measured from the edge of the flue elbow IMPORTANT The maximum equivalent length of concentric flue is 8 metres Additional bends may be fitted in the concentric flue but th
40. e equivalent length must be reduced by 1 metre 93 bend or 0 5 metres 45 bend 7 60 1 metre extensions including support bracket and additional 93 amp 45 elbows are available Any additional 93 amp 45 elbows must be accounted for when calculating flue lengths NOTE Permitted positions of the plume outlet relative to doors windows etc are the same as for conventional concentric flues as detailed in the main Installation amp Servicing Instructions and BS5440 Pt 1 It is NOT necessary to fit a terminal guard over the air inlet or the plume outlet 60 Exhaust metres X x T 2 3 t 3 8 o Ko 0 1 2 3 4 5 6 T 8 Concentric 60 100 Flue metres Y Example 1 Flue Lengths N ot Permissible 60 Exhaust metres X Flue Lengths OK 2 3 2 3 4 6 6 7 8 9 Concentric 60 100 Flue metres Y Example 2 Flue Lengths O K 4 5 6 1 8 9 Concentric 60 100 Flue metres Y Example 3 60 Exhaust Additional Accessories A 93 Elbow B 45 Elbow Pair C 1 metre 60 Extension Baxi Heating UK Ltd 2012 Concentric 60 100 Flue 5121369 5121370 5121368 45 Elbow 93 Elbow Support Bracket ru 1 metre Extension 1 metre supplied in kit 9 0 Plume Displacement Determining Permissible Lengths In the graph the solid line diagonal represents the relationship between
41. e facia panel 5 Fit the new switch ensuring that it is correctly positioned and reassemble in reverse order 49 dees ee 14 0 Changing Components Gas Valve Fig 103 IMPORTANT After replacing the valve the CO 2 must be checked and adjusted as detailed in Section 15 0 Setting the Gas Valve O nly change the valve if a suitable calibrated combustion analyser is available operated by a competent person see section 13 1 Sensing Pipe Power Lead 4 1 Turn the gas cock off and undo the nut on the gas feed elbow under the boiler 2 Remove the screws securing the gas valve to the boiler bottom panel 3 Pull off the power lead earth lead and sensing pipe Earth Lead 4 a 4 Undo the nut on the gas pipe at the gas air inlet and the gas ae en valve Remove the pipe taking care not to lose the sealing washers Remove the valve Fig 103 5 Reassemble in reverse order ensuring that all seals are in place and the injector is fitted NOTE To assist the boiler to light prior to final setting use a Suitable hexagon key to wind out the Throttle adjustment screw until it is flush with the valve body then Throttle Adjustment Screw e turn the screw 4 full turns clockwise Fig 103a If the boiler will not light or the correct CO cannot be achieved contact the heateam technical helpline EYES Expansion Vessel Fig 104 1 D rain the primary
42. e pipe diameter been increased and weatherproof insulation fitted Yes ALL INSTALLATIONS co L io or co L loom OR CO CO Ratio If required by the manufacturer record the following The heating and hot water system complies with the appropriate Building Regulations Yes _ The boiler and associated products have been installed and commissioned in accordance with manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Yes Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer 6 2 THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk 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 appro
43. ection 15 1 1 to 15 1 6 5 Remove the plug from the flue sampling point insert the analyser probe and obtain the CO CO zratio This must be less than 0 004 6 If the combustion reading CO CO zratio is greater than this and the integrity of the complete flue system and combustion circuit seals has been verified and the inlet gas pressure and gas rate are satisfactory either Perform the Annual Servicing Inspection Section 13 2 amp re check Adjust the gas valve Section 15 0 amp re check e Replace the gas valve Section 14 24 amp re check Annual Servicing Inspection 1 Ensure that the boiler is cool 2 Ensure that both the gas and electrical supplies to the boiler are isolated 3 Slacken the screws securing the facia panel Lift the outercase panel so that its securing tabs are clear of the facia Remove the panel allowing the facia to hinge down Fig 73 4 Remove the screws securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case Fig 74 5 Unscrew the sump from the bottom of the condensate trap assembly Fig 75 and remove any deposits from the sump and trap Clean as necessary and replace the sump Burner Sensing Electrode Spark Ignition Electrode N Electrode Position Fan Collector and Cover Assembly Electrode Leads Fig 76 Fig 77 Gas Inlet Pipe Hall Effect
44. ed in conjunction with with the integral timer The integral timer can be replaced with the blanking plate supplied in the installation kit and wiring connected as in Fig 61 6 Remove the link between terminals 1 amp 2 The 230V supply at terminal 2 must be connected to the thermostat The switched output from the thermostat must be connected to terminal 1 Figs 60 amp 61 If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Figs 60 amp 61 7 Ensure that the external control input cable s have sufficient slack to allow the control box to drop down Tighten the cable clamp on the boiler chassis 8 Replace the terminal block cover routing the external control input cable s through the second cut out Preliminary Electrical Checks 1 Prior to commissioning the boiler preliminary electrical system checks should be carried out 2 These should be performed using a suitable meter and include checks for Earth Continuity Resistance to Earth Short Circuit and Polarity 35 11 0 Commissioning Commissioning the Boiler 1 Reference should be made to BS EN 12828 amp 14336 when commissioning the boiler 2 At the time of commissioning complete all relevant sections of the Benchmark Checklist at the rear of this Screw publications 3 O pen the mains water supply to the boiler eaten 4 0 pen all hot water taps to purge the DHW system ees a 5
45. electrodes for up to 5 seconds and for 3 Error 133 flashing attempts Go to section F NO Burner lights Burner does not stay lights YES Error 133 flashing 9 after 5 seconds Go to section 1 YES Burner output modulates to Reduce DHW flow rate NO Clean DHW NTC sensor maintain the temperature set Burner modulates and DHW heat exchanger S Error 130 flashing Go to section M Close DHW tap YES DHW flow sensor sensesno YES YES YES O peration sequence flow Burner goes out Fan stops after 10 seconds Pump runs for 30 seconds 56 Baxi Heating UK Ltd 2012 reset position for 5 seconds YES YE 18 0 Fault Finding Fault Finding Solutions Sections Is there 230V at 1 Main terminals L and N ne 2 Main terminal fuse NO NO SS Check electrical supply Replace fuse Check wiring Display illuminated Replace PCB PCB X1 connector terminals 1 2 B Is there 230V at 1 Pump YES If pump jammed release NO Replace pump 2 PCB X3 connector terminals 3 amp 4 NO Replace PCB YES Change pump supply cable Ca CH system pressure less than 0 5 bar ul Re pressurise system Check connection water pressure switch terminal YES Replace water COM NO and PCB connector pressure switch X 400 terminals 3 4 2 Check the tap of the automatic air NO Open the automatic air vent vent is opened D 1 Fan connections correct at fan PCB YES X2
46. emperature Control to Hot Water Cylinder Thermostat and Programmer Timer Combination Boiler Heating Zone Valves Fitted Not Required Hot Water Zone Valves Fitted Not Required Thermostatic Radiator Valves Fitted Not Required __ Automatic Bypass to System Fitted Not Required _ Boiler Interlock Provided E ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litres CENTRAL HEATING MODE Measure and Record Gas Rate m hr OR ftYhr Burner Operating Pressure if applicable mbar OR Gas Inlet Pressure mbar Central Heating Flow Temperature C Central Heating Return Temperature C COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No If yes and if required by the manufacturer has a water scale reducer been fitted Yes No What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas Rate mhr OR ft hr Burner Operating Pressure at maximum rate mbar OR Gas Inlet Pressure at maximum rate mbar Cold Water Inlet Temperature C Hot Water has been checked at all outlets Yes Temperature C Water Flow Rate l min CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5545 BS6798 Yes If the condensate pipe terminates externally has th
47. en the tap is reopened the system will flush 11 Remove the blanking plug s pressure gauge and flushing equipment from the appliance if used 12 Continue with the installation and commissioning 13 The filling loop must be disconnected and completely removed after the system is pressurised 14 Depending upon the type of kit supplied either hand tighten the two previously removed blanking caps to the stop valve and double check valve or use the caps supplied in the kit 31 W al Plate 10 0 Installation Fitting The Boiler Sealing 1 Lift the boiler using the Lifting Points as shown by the W ashers shaded areas Fig 45 The boiler should be lifted by TW O J PEO PLE Engage the slots at the top rear of the boiler on the wall plate Fig 46 see Safe Manual Handling page 5 2 Ease the boiler forwards and remove the sealing caps from the boiler connections NOTE A small amount of water may drain from the boiler once the caps are removed 3 Insert the sealing washers between the valves and pipes on Fig 46 the wall plate and the boiler connections THE RUBBER WASHERS MUST BE USED ON THEGASCONNECTION 5 d Lifti age Lo 4 Tighten all the connections uogested Litting Points Remove Sealing Caps from shown as shaded area under the Boiler after lifting into position Fitting the Safety Pressure Relief Discharge Pipe Fig 47 1 Remove the discharge pi
48. ents Signature Service 10 Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature 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 POTTERTON A Trading Division of Baxi Heating UK Ltd 3879156 Brooks House Coventry Road W arwick CV34 4LL After Sales Service 0844 871 1560 Technical Enquiries 0844 871 1555 W ebsite www potterton co uk e amp oe PART OF BDR THERMEA Baxi Heating UK Ltd 2012 7202085 07 5 12
49. er installation If one of the dimensions Flue Deflector Kit part no 5111068 D E F G orH 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 IMPORTANT Under car ports we recommend the use of the plume displacement kit e The terminal position must ensure the safe and nuisance free dispersal of combustion products Ky Terminal sin rm Assembly Sh i d i ig Plume 3 4 Displacement Kit IMPORTANT If fitting a Plume Ly i Displacement Flue Kit the air inlet i E must be a minimum of 150mm from 1 Z 8 ECTS any opening windows or doors see Top View Rear Flue MEG gt Section 9 0 Fig 17 Se YN 1 Property Boundary Line as Air Inlet a E O pening W indow va or Door 150mm Fig 18a _ MIN R N a S08 el a f 9 F JK L cI A H TORN G H H Likely flue positions requiring a flue terminal guard Fig 18 20 Baxi Heating UK L
50. erature Control Fig 66 Temperature Control Selector Switch Display wE E M Nz z dp OC LP 4 X Central H eating Domestic Hot W ater Temperature Control Temperature Control Gas Pressure Test Point Fig 66a Gas Valve Fig 70 Fig 71 Baxi Heating UK Ltd 2012 2 11 0 Commissioning Check the O perational W orking Gas Inlet Pressure 1 Ensure that all controls are calling for heat and the selector switch is in the central heating and hot water position ff The current boiler temperature is shown on the display 2 It is necessary to set the boiler to Calibration Mode 3 Turn both temperature control knobs fully anticlockwise then quickly turn the DHW temperature knob 4 clockwise twice and back fully anticlockwise Fig 66 4 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash Figs 67 amp 68 5 Turn CH temperature control knob fully clockwise As the knob is turned the display will change from 0 to 00 Fig 69 indicating maximum rate then revert to P alternating with the current boiler temperature Figs 70 amp 71 6 W ith the boiler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point Fig 66a is in accordance with B S 6798 amp B S 6891 7 Ensure that this inlet pressure can be obtained with all o
51. examples refer to the Current LEE W iring Regulations and reference must be made to the relevant requirements In GB this is the current LEE W iring Regulations and 225m Building Regulations In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules le eee ee 2 If the integral timer is replaced with the blanking plate supplied in the installation kit it can be fitted in Zone 2 0 6 m Fig B In GB Only 16 Baxi Heating UK Ltd 2012 Examples are shown of the following methods of termination i to an internal soil amp 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 amp vent pipe vi to a drain or gully with extended external run amp 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 215mm 32mm Insulation vent pipe 450mm min 450mm is applicable to properties up to 3 storeys For multi storey building installations consult BS 6798 Boiler receptacle Baxi Heating UK Ltd 2012 7 0 Site Requirements i Termination to an internal soil and AAA ii Ex
52. g Front 5 mm Min In O peration L H Side 5 mm Min RH Side 5 mm Min In O peration This is the MIN IMUM recommended dimension Greater clearance than this will aid installation and maintenance W eights kg 24 28 33 Packaged Boiler Carton 486 492 51 Installation Lift W eight 436 442 46 Metre wg 0 200 NO Class 5 Central Heating Primary Circuit Pressures bar Safety Discharge 3 ax O perating 25 in O perating 0 5 Recommended O perating Range 1 2 DHW Circuit bar Pressures ax O perating 8 in O perating 0 15 Flow Rates 24 28 33 l min l min l min DHW Flow Rate 30 C Rise 1143 133 15 7 DHW Flow Rate 35 C Rise 9 8 115 135 in W orking DHW Flow Rate 2 2 2 IMPORTANT W here Low Flow Taps or Fittings are intended to be used in the DHW system connected it is strongly recommended that the DHW flow rate DO ES NOT fall below 2 5 min This will ensure reliable operation of the DHW function Pump Available Head See graph below Expansion Vessel For Central H eating only Integral with appliance bar Min Pre charge Pressure 05 24 28 33 Max Capacity of litre litre CH System 125 155 Primary W ater Content of Boiler unpressurised 25 28 Temperatures C H Flow Temp adjustable 25 C to 80 C max 5 C D H W Flow Temp adjustable 35 C to 60 C max 5 C dependent upon flow rate 400 600 800 1000 1200 Flow Rate l h 5 0 Dimensions
53. g the fan to the venturi and the venturi to the collector IMPORTANT W hen fitting the new venturi ensure the arrows on it s base point into the collector Fig 84 4 Examine the seals and burner gasket replace if necessary 5 Reassemble in reverse order ensuring that the injector is in place Injector Fig 82 1 Remove the collector and fan assembly as described in section 14 3 2 Extract and replace the injector and reassemble in reverse order 43 Cover Burner Gasket Extension Piece i 24 amp 28 models Venturi P a Collector Fig 85 Heat Exchanger Rear Insulation Spark Electrode Insulation Fig 75 Electrode Sensing Leads Electrode 44 Baxi Heating UK Ltd 2012 14 0 Changing Components Burner Fig 85 1 Undo the screws securing the collector to the cover and venturi O n 24 amp 28 models there is an extension piece fitted to the cover remove this also 2 W ithdraw the burner from the cover and replace with the new one 3 Examine the gasket replacing if necessary 4 Reassemble in reverse order Insulation Fig 86 1 Remove the electrode leads noting their positions Also remove the electrodes as described in section 14 2 2 Undo the screws securing the collector to the venturi and the nuts holding the cover to the heat exchanger Draw the collector and cover assembly aw
54. grees 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 Flue Dimensions The standard horizontal telescopic flue kit allows for lengths between 100mm and 685mm from elbow to terminal Fig 19 The maximum permissible equivalent flue
55. hts on after 5 seconds Go to section I Check the Central H eating NTC sensor Go to section E Burner output modulates to Error 130 flashing maintain the temperature set gt Go to section M YES Pump continues to run for 3 YES Bumergoesout Fan stops after 10 seconds ee minutes Operation ape room thermostat open PE Baxi Heating UK Ltd 2012 3 way valve is open to Central 18 0 Fault Finding Domestic Hot W ater Follow operational sequence Turn selector switch to We Go to section A The display illuminates Error 110 flashing YES Turn the selector switch to YES Ifthe error 110 is still flashing Error 133 flashing gt reset position for 5 seconds a Go to section Error 20 28 or 50 flashing Go to section E YES ae Error 119 flashing ne Go to section C Go to section B Turn Domestic Hot W ater YES thermostat to Maximum Open DHW tap fully Is mains water filter and DHW Hall Effect sensor NO DHW flow rate more than2 YES assembly clean operated red neon on the limin Is the magnetic detector free sensor illuminated to move in the Hall Effect 3 way valve is open to NO or Domestic Hot W ater circuit i SE SON P NO Error 125 flashing Pumpruns Goto section NO Error 160 flashing i Go to section D sensor NO Error 160 flashing Go to section L Go to section H iE Turn the selector switch to the Spark at ignition
56. ilable as accessories 21 Vertical IMPORTANT All flue systems must be securely supported at least once every metre Suitable pipe supports are available as accessories Vertical Flues Twin Pipe 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 O ne 91 5 bend or two 135 bends can be included without reduction of the flue length If further elbows are required the flue length must be reduced by the following amounts 1 metre for each 91 5 bend il 0 5 metre for each 135 bend 1 metre 22 Baxi Heating UK Ltd 2012 120mm Min t lt 2 a N Roof Terminal This bend is equivalent to 600mm Min apart 8 0 Flue O ptions Twin amp Vertical Flue Systems 1 Maximum permissible equivalent flue lengths are 60 100 80 125 Vertical Concentric 10 metres 20 metres Vertical Twin Pipe 15 metres 2 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 135 bend 0 5 metres 93 bend 1 0 metres Twin Flue Pipe 135 bend 0 25 metres 91 5 bend 0 50 metres The elbow supplied with the standard horizontal telescopic flue kit
57. iler is fitted in a room containing a bath or shower reference must be made to the relevant requirements In GB this is the current LEE W iring Regulations and Building Regulations In IE reference should be made to the current edition of l S 813 Domestic Gas Installations and the current ETC rules 4 If the boiler is to be fitted into a building of timber frame y construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE UP 7 150mm Min Gas Installations in Timber Framed H ousing Fig 8 ee ae This is the MINIMUM recommended dimension Greater clearance than this will aid installation and maintenance y At least 1 5 A Clearances Figs 8 amp 9 1 A flat vertical area is required for the installation of the boiler 2 These dimensions include the necessary clearances around the boiler for case removal spanner access and air movement A dditional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler 450mm Min For Servicing Purposes In O peration Fig 9 Baxi Heating UK Ltd 2012 15 7 0 Site Requirement Ventilation of Compartments Gas Service Cock 1 W here the appliance is installed in a cupboard or compartment no air vents are required 2 BS 5440 Part 2 refers to room sealed appliances installed in compartments The a
58. is not included in any equivalent length calculations NOTE Flue length is measured from point i to ii as shown Mini Terminal on Air Duct sited in loft The total equivalent length for this example is 6 5 metres Equivalent N of Sub total Length Value fittings pipes 135 bend 915 bend Equivalent Length Air Duct 6 5m Sub total Equivalent N of Length Value fittings pipes 1m extension 135 bend 91 5 bend Equivalent Length Flue Duct 6 5m Baxi Heating UK Ltd 2012 8 0 Flue Options Flue Accessories Key Accessory Size Code No FLUEGROUPA Concentric Flue System 100mm diameter A3 Telescopic Internal Flue Kit 315 500mm 5119654 A2 Telescopic Flue inc elbow 315 500mm 5118069 A Horizontal Flue Terminal inc elbow 5118489 B Flue Extension 1000mm 5111074 C Flue Bend 93 5111075 D Flue Bend 135 5111076 D Flue Bend pair 135 5111085 U Pipe Support painted 100mm 5111080 R Vertical Flue Adaptor 5111070 P W all Liner 5111067 S Flue Terminal D eflector 5111068 FLUE GROUP N Twin Flue System 80mm diameter E Flue Extension pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend 2 pair 135 5111086 J Vertical Flue Boiler Adaptor Kit 720089801 H Vertical Flue Adaptor 5111084 Ww Pipe Support pair 80mm 5111081 Y Flue Termination Kit horizontal termination 80mm 5120172 Z Single Terminal 80mm 5121791 Q Adaptor 60 80 5121792 T Pitched Roof Terminal 25
59. issible 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 amp 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 aMINIMUM 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 17 7 0 Site Requirement Condensate Drain cont iii Termination to a drain or gully 11 W hen discharging condensate into a soil stack or waste pipe the effec
60. it and undo the nut on the pressure gauge capillary 2 Undo the screws securing the gauge retaining bracket 3 Remove the bracket and gauge assembly D epress the barbs on the side of the gauge and remove the retaining bracket Pressure Gauge 4 Examine the sealing washer replace if necessary 5 Reassemble in reverse order IVAR Hall Effect Sensor Fig 96 1 Ease the sensor upwards off the hydraulic inlet manifold assembly 2 Disconnect the electrical plug from the sensor T 3 Connect the plug to the new sensor Carefully fit the new pes aie Gauge sensor to the hydraulic assembly ensuring it is fully down Capillary Hall Effect Sensor i IVARI Pressure Relief Valve Fig 97 1 Drain the boiler primary circuit 2 Disconnect the discharge pipe from the valve U sing a suitable hexagon key undo the grub screw sufficiently to release the valve 3 N ote the orientation of the valve rotate it and withdraw it from the manifold EN is lt 4 Fit the new valve and O ring seal and set to the previously noted orientation Reassemble in reverse order gz O ringseal D ischarge Pipe Baxi Heating UK Ltd 2012 47 Plate Heat Exchanger Sc LH Location Stud Q Fig 98 Rubber Seal Motor Unit Multi pin Plug Retaining Clip Valve Assembly Press
61. itch to the Reset position for a minimum of 5 seconds when E110 E130 amp E133 are displayed it is possible to relight the boiler 4 If this does not have any effect or the codes are displayed regularly further investigation is required 18 0 Fault Finding Refer to Section 16 0 Illustrated W iring Diagram for position of terminals and components Central H eating Follow operational sequence do Turn selector switch to iJ are The display illuminates PASSES YES Error 110 flashing ar Error 130 flashing YES Turn the selector switch to YES If the error 110 is still flashing Error 133 flashing reset position for 5 seconds Go to section J Error 20 28 or 50 flashing Go to section E Go to section C Error 119 flashing Ensure controls are set to demand and verify the contacts are closed Turn Central Heating Ensure all controls and thermostat to Maximum integral clock if fitted are Go to section B Pump runs calling for heat YES Ensure that primary Error 125 or 193 flashing circulation is O K amp that there is no blockage NO ee H eating circuit Go to section K YES Fan t NO Error 160 flashing uns Go to section D YES Fan runs at correct speed oe 2 Error 160 ashing p Go to section L Spark at ignition electrodes for up to 5 seconds and for 3 Error 133 flashing attempts CN Go to section F Burner does not stay alights YES Error 133 flashing Burner lig
62. l 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 e The integrity of the complete flue system and the flue seals e The integrity of the boiler combustion circuit and relevant seals as described in Section 13 2 e The operational gas inlet pressure as described in Section 11 2 1 to 11 2 7 and the gas rate as described in 11 2 8 e The combustion performance as described in Check the Combustion Performance 13 1 4 to 13 1 6 below 3 Competence to carry out Checking Combustion Performance B S 6798 Specification for Installation amp Maintenance of Gas Fired Boilers not exceeding 70kW advises that e 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 e The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN 50379 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 zratio 4 Set the boiler to operate at maximum rate as described in S
63. llation of gas fired hot water boilers BS 5440 Part 1 Flues BS 5440 Part 2 Ventilation BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems In IE the following C odes of Practice apply Standard Scope LS 813 Domestic Gas Installations The following standards give valuable additional information BS 5546 Installation of hot water supplies for domestic purposes BS EN 12828 Heating systems in buildings BS EN 14336 Installation amp commissioning of water based heating systems BS 7074 Expansion vessels and ancillary equipment for sealed water systems Treatment of water in domestic hot water central heating systems BS 7593 Safe Manual Handling The following advice should be adhered to from when first handling the boiler to the final stages of installation and also during maintenance General 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 amp 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 TW O PEO PLE Do not handle or lift unless you feel physically able W ear appropriate Personal Protection Equipment e g protective gloves safety footwear etc Preparation C
64. n switch the timer will allow either constant operation timed operation or central heating off Move the switch button by sliding to the desired position Three position switch Fig 71a I Constant Top position The heating will be on constantly irrespective of the position of the tappets T he heating will be controlled by the main thermostat on the appliance and or any external controls Oo Timed Central position The heating will operate according to the position of the tappets and be controlled as above 0 O ff Bottom position No central heating Domestic hot water will operate on demand To set the time of day Turn the timer outer bezel clockwise to align the pointer with the correct time to the nearest 15 minutes ensuring that A M P M is considered Do not at any time attempt to turn the bezel anti clockwise To set the timed heating program Decide which times of the day the central heating is required The heating will operate when the white tappets are set to the outer edge of the bezel To ensure the heating stays O FF set the required tappets inwards towards the centre of the bezel Each tappet represents 15 minutes For example If the heating is not required between 10 A M and 11 A M the four tappets anticlockwise from the 10 A M will be set inwards Fig 71b 12 0 Completion Completion 1 Instruct the user in the operation of the boiler and system explaining the operational sequence
65. ng a suitable hexagon key after removing the cap Fig 112 Turning anti clockwise will reduce the CO 2 Clockwise will increase the CO 2 Reduce CO2 Increase CO2 at max rate at max rate a Val ee Mec ne If the CO2 is reset at minimum Seas Fig 112 11 The Calibration Function is maintained for 20 minutes rate it must be rechecked at unless the maximum CH temperature is exceeded The maximum rate again and adjusted Do not turn the adjustment function can be disabled at any time by turning the right screws more than 1 8 of a turn at hand knob a time Allow the analyser reading to settle before any further 12 Check the Combustion Performance CO CO ratio adjustment This must be less than 0 004 if required If the CO is reset at maximum rate it must be rechecked at minimum rate and adjusted if required Baxi Heating UK Ltd 2012 51 16 0 Electrical Illustrated W iring Diagram b il Flue Sensor Central Heating NTC Sensor DHW NTC Sensor Overheat Stat Hall Effect Sensor Water Pressure Switch 987654321 bk Control PCB v i a bk X501 E A 10987654321 R x x z annnm fe TT III I Flame Sensing Electrode ka Spark Generator Diverter Valve Ignition Electrode Mains Input Cable br brown g green bk black gly green yellow b blue r red w white 52 Baxi Heating UK Ltd 2012 17 0 Short Pa
66. nt standards and water supply regulations 2 Your attention is drawn to for GB Guidance G17 to G24 and recommendation R17 to R24 of the W ater Regulations Guide for IE the current edition of IS 813 Domestic Gas Installations 3 The W ater Regulations recommendations for England and W ales prohibits backflow from appliances into the wholesome water supply due to thermal expansion However this type of instantaneous combination boiler with less than 15 litres of stored capacity does not require any backflow prevention device as any thermal expansion is accommodated within the appliance It is possible in certain circumstances that other cold water demands e g washing machines flushing of W C s may affect the DHW function of the boiler In these instances the fitting of a backflow prevention device and expansion vessel is recommended 4 Also if there is an existing check valve loose jumpered stop cock water meter or water treatment device already fitted to the wholesome water supply connected to the boiler domestic hot water DHW inlet supply then a suitable expansion device may be required 5 The boiler s maximum working mains pressure is 8 bar therefore all pipework connections fittings etc should be suitable for pressures in excess of 8 bar A pressure reducing valve must be fitted for pressures in excess of 8 bar The manufacturer of any outlet fittings such as a shower valve may require a lower maximum
67. o 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 W hen 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 W here possible transport the boiler using a sack truck or other suitable trolley Always grip the boiler firmly and before lifting feel where the weight is concentrated to establish the centre of gravity repositioning yourself as necessary See the Installation section of these instructions for recommended lift points Remember The circumstances of each installation are different Always asses the risks associated with handling and lifting according to the individual conditions If at any time when installing the boiler you feel that you may have injured yourself STO P 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 2012 5 CONTENTS Section Page 10 Introduction 7
68. oiler will not operate and the integral timer will require resetting once the selector switch is set to either Position i or Position ii Frost Protection Mode 1 The frost protection mode is integral to the appliance and functions only with the selector switch see Section 2 1 in the domestic hot water and central heating position If the system temperature falls below 5 C then the boiler will fire on its minimum setting until a flow temperature of 30 C is reached Pump Protection 1 With the selector switch see Section 2 1 in either the central heating or central heating and domestic hot water position the pump will automatically operate for 1 minute in every 24 hours to prevent sticking 10 Appliance Type Cis C3 Css Appliance Category CAT Izp Heat Input CH Net Max Min 24 model kW 20 5 7 28 model kW 247 9 33 model kw 28 9 97 Heat Input CH G ross Max Min 24 model kW 22 7 78 28 model kW 274 10 33 model kw 321 108 Heat Output CH Non Condensing Max Min 24 model kW 20 6 8 28 model kW 24 8 7 33 model kW 28 9 4 Heat Output CH Condensing Max Min 24 model kW 21 74 28 model kw 25 9 95 33 model kw 30 3 10 2 Heat Input DHW N et Max 24 model kW 247 28 model kW 28 9 33 model kW 34 Heat Input DHW Gross Max 24 model kW 274 28 model kW 32 1 33 model kW 37 Heat Output DHW Max 24 model kW 24 28 model kW 28 33 model kW 33 Max Gas Rate Natur
69. ough the hole from outside the building 5 If required the flexible flue trim should be fitted prior to this as it cannot be fitted after Use the large Jubilee clip to secure the trim to the flue See Fig 20 trim shown dotted with the screw part of the clip at the bottom 6 Connect any extensions or elbows that are being used to the concentric assembly Engage the extension elbow or concentric assembly in the boiler flue elbow Fit the boiler flue elbow to the boiler adaptor 7 Ensure that the concentric assembly and any extensions fall back to the boiler at an angle of at least 1 5 and that the external air inlet is to the bottom 8 Use suitable brackets to support the concentric assembly and any extensions and make good inside and outside 9 The 609 exhaust can now be fitted Slide the adaptor over the plain end of the 608 exhaust Fig 22 and engage the exhaust in the terminal Slide the adaptor down over the spigot Mark and drill the adaptor using a 2mm bit as shown in Fig 21 Secure the adaptor to the spigot using one of the screws supplied 10 If it is necessary to shorten the 60 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 60 exhaust and mark on the wall a suitable position for the support bracket If extensions are being used a support bracket is supplied in each kit 12 Drill the wall and fit the bracket s
70. pe from the kit 2 Determine the routing of the discharge pipe in the vicinity of the boiler Make up as much of the pipework as is practical including the discharge pipe supplied 3 The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside discharge point IMPO RTANT Make all soldered joints before connecting to the pressure relief valve Condensate Drain see section 7 7 Pressure Relief Valve 1 Connect the condensate drain to the trap outlet pipe Ensure the discharge of condensate complies with any national or local regulations in force see British Gas Discharge Pipe Guidance N otes for the Installation of Domestic Gas Condensing Boilers 2 The connection will accept 21 5mm in plastic overflow pipe which should generally discharge internally into the household drainage system If this is not possible discharge into an outside drain is acceptable 32 Baxi Heating UK Ltd 2012 W all Thickness Z Flue Elbow Apply Lubricant for ease of assembly Ensure Elbow is fully engaged into Boiler Adaptor Adaptor Fig 50 GZ W all Thickness Fig 51 W aste os
71. ppliance will run sufficiently cool without ventilation 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 S 813 Domestic Gas Installations 2 The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock Fig 10 3 Ensure that the pipework from the meter to the appliance is of adequate size Do not use pipes of a smaller diameter than the boiler gas connection 22mm p_Zone2 Window 4 Electrical Supply Recess 1 External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current LEE W iring Regulations In IE reference should be made to the current edition of ET CI rules 2 The mains supply is 230V 50H fused at 3A W indow Recess NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the Zone 2 appliance Connection may be via a fused double pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only In GB O nly Bath amp Shower Rooms Ceiling W indow Recess 1 If the boiler is installed in a room containing a bath or Zone 2 O utside Zones shower it CANNOT be fitted in Zone 1 or Zone 2 Figs A amp B shows Zone dimensions for a bathtub For other
72. priate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls Service 1 Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Service 3 Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Service 5 Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Service 7 Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Service 9 Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Service 2 Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Service 4 Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Service 6 Date Engineer Name Company Name Telephone No Operative ID No Comments Signature Service 8 Date Engineer Name Company Name Telephone No Gas Safe Register No Comm
73. rts List Short Parts List Key Description Manufacturers 426 No Part No 311 Fan 5121447 426 Motor 3 W ay Valve 5132452 315 Igniter Electrode 720222801 316 Sensing Electrode 720222901 422 Gas Valve 720301001 404 Hall Effect Sensor 5114767 306 Burner 24 28 5122149 Burner 33 5114697 419 W ater Pressure Switch 5114748 400 Plate Heat Exchanger 24 28 248048 Plate Heat Exchanger 33 5114708 415 Pump 248042 421 NTC Sensor 5114725 420 O verheat Thermostat 5114729 504 Pressure Gauge 248090 503 PCB 24 5121862 PCB 28 720043401 PCB 33 720795201 302 Flue Safety NTC 5114747 302 421 420 504 Baxi Heating UK Ltd 2012 53 NOTE When instructed to turn the selector to the reset position turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler Table Of Error Codes Central Heating NTC Fault Flue N TC Fault Hot W ater NTC Fault Safety Thermostat O perated W ater Pressure Switch N ot O perated Circulation Fault Primary Circuit Flue NTC Operated Interruption O f Gas Supply or Flame Failure Fan or Fan W iring Fault Pre Circulation Fault 54 Baxi Heating UK Ltd 2012 18 0 Fault Finding Initial Fault Finding Checks 1 Check that gas water and electrical supplies are available at the boiler 2 Electrical supply 230V 50 Hz 3 CH water system pressurised
74. st point on the gas valve is a MINIMUM of 17mbar 2 Check and correct if necessary 1 The mechanical set of the gas valve CO 2 values see instruction 2 Flame sensing electrode and lead connections 3 Flame sensing electrode position Replace PCB Replace flame sensing electrode Flame current should be more than 0 5 u A 1 Overheat thermostat operated or Allow to cool Continuity faulty i e continuity across across thermostat terminals thermostat terminals more than 1 5 ohm ue Replace safety thermostat Replace PCB Is there 230V at 1 Motor 3 way valve a ES Replace motor 3 way valve 2 PCB X3 connector terminals NO Replace PCB 5 amp 6 central heating mode 5 amp 7 domestic hot water mode Change pump supply cable Fan connections correct at fan YES AGEN PCB X 401 connector terminals 5 6 7 amp 8 1 Temperature sensors faulty Cold resistance approximately 10kQ 25 C CH sensor 20kQ 25 C Flue sensor resistance reduces with increase in temp Replace sensor 2 if pump is running the heat exchanger could be YES Replace heat exchanger obstructed Baxi Heating UK Ltd 2012 59 19 0 Pages for Notes 60 Baxi Heating UK Ltd 2012 19 0 Pages for N otes Baxi Heating UK Ltd 2012
75. 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 e Gas Safety Installation amp Use Regulations e The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations N orthern Ireland The W ater Fittings Regulations or W ater Byelaws in Scotland e The Current LEE W iring Regulations W here no specific instructions are given reference should be made to the relevant British Standard C ode of Practice In IE the installation must be carried out by a competent Person and installed in accordance with the current edition of LS 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETC rules for electrical installation All systems must be thoroughly flushed and treated with inhibitor see section 6 2 Codes of Practice refer to the most recent version In GB the following C odes of Practice apply Standard Scope BS 6891 Gas Installation BS 5546 Installation of hot water supplies for domestic purposes BS EN 12828 Heating systems in buildings BS EN 14336 Installation amp commissioning of water based heating systems BS 6798 Insta
76. t W ater Temperature Control Venturi Air Gas Collector Combustion Box Cover amp Burner Igniter Burner O n Light Central Heating Mode Light Domestic Hot W ater Mode Light D isplay Integral Timer Central Heating Circuit 18 CH A Fig 2 Key 1 Primary Heat Exchanger 2 Burner 3 Ignition Electrodes 4 Flame Sensing Electrode 5 Gas Valve 6 Pump 7 Automatic Air Vent 8 Plate Heat Exchanger Automatic By pass 9 Flow Sensor with Filter amp Regulator 10 Safety Pressure Relief Valve 11 Boiler Drain Point 12 Heating Return 13 Cold W ater Inlet O n O ff Valve and Filter 14 Gas Inlet Domestic Hot W ater Circuit X Domestic Hot W ater O utlet H eating Flow Pressure Gauge W ater Pressure Sensor Fan D iverter Valve Assembly Diverter Valve Motor Domestic Hot W ater Flow Temperature Sensor Safety Thermostat Central Heating Temperature Sensor Expansion Vessel Heat Exchanger Air Vent 27 C M AE ou 3 4 26 O 7 20 25 8 i 24 22 9 TI 11 23 Baxi Heating UK Ltd 2012 110 17
77. taps on the wall plate at this point Either one of two types of loop kit will be supplied both function in the same way differing only in detail 2 The filling loop is to be connected between the mains cold water inlet and central heating return isolation taps 3 The loop and valves must be connected as described in the instructions supplied with it 4 Note the orientation of the flow direction arrows on the stop valve and double check stop valves 5 Remove the blanking caps from the mains cold water inlet and central heating return isolation taps Fig 44a Connect the valves to the taps ensuring that the fibre washers supplied are used on these joints 6 Connect the temporary loop ensuring that the seals are fitted To fill test and flush if required Fig 44b 7 Take the blanking plugs from the kit and using washers supplied with the boiler connect them to the central heating flow and return taps and the cold inlet tap The system can now be filled by opening the cold inlet supply and stop valves 8 If desired a suitable gauge can be connected to one of the taps so that the system may be accurately pressurised 9 All joints fittings and system components can now be examined for soundness at operating pressure 10 The system can be flushed by turning off the central heating tap and connecting a suitable fitting to the loose nut From the fitting a hose pipe can be run to the nearest convenient drain W h
78. td 2012 Plume Displacement Kit 60 100 1M Extensions 45 amp 93 bends are also available see Section 9 0 NOTE Horizontal flue pipes should always be installed with a fall of at least 15 from the terminal to allow condensate to run back to the boiler This bend is equivalent to 1 metre This bend is equivalent to 1 metre Total equivalent length A B C 2x90 Bends Baxi Heating UK Ltd 2012 8 0 Flue Options Horizontal Flue Systems 1 The standard flue is suitable only for horizontal termination applications 2 All fittings should be fully engaged The approximate engagement is 40mm Apply soap solution to the seal on each fitting to aid assembly 3 Maximum permissible equivalent flue lengths are 60 100 80 125 Horizontal Concentric 10 metres 20 metres 4 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 135 bend 0 5 metres 93 bend 1 0 metres Twin Flue Pipe 135 bend 0 25 metres 91 5 bend 0 50 metres 4 The elbow connected to the boiler adaptor is not included in any equivalent length calculations 5 The illustrations opposite show examples of permissible flue systems NOTE Flue length is measured from point i to ii as shown IMPORTANT All flue systems must be securely supported at least once every metre Suitable pipe supports are ava
79. tem risking damage to pump and valves boiler noise and circulation problems 2 W hen fitting new systems flux will be evident within the system which can lead to damage of system components 3 All systems must be thoroughly drained and flushed out using for example Sentinel X 300 or X 400 or Fernox F3 They should be used following the flushing agent manufacturer s instructions 4 System additives corrosion inhibitors and flushing agents descalers should comply to BS7593 requirements e g Sentinel X 100 and Fernox MB 1 which should be used following the inhibitor manufacturer s instructions 5 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 6 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 7 For information or advice regarding any of the above contact Technical Enquiries Bypass 1 The boiler utilises the primary side of the DHW plate heat exchanger as an automatic integral bypass System Control 1 A 24 hour electro mechanical timer is supplied fitted to the boiler 2 Further external controls e g room thermostat should be fitted to optimise the economical oper
80. ternal termination via internal discharge branch e g sink waste downstream Pipe must terminate above water level but below surrounding surface C ut end at 45 y M It is NOT RECOMMENDED to connect upstream of the sink or other waste water Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEW ORK CORRECTLY W ILL AFFECT THE RELIABLE OPERATION OF THE BOILER CAREFUL CONSIDERATION MUST BE GIVEN TO THE POSSIBILITY OF THE PIPEW ORK BEING SUBJECT TO FREEZING CONDITIONSAND APPROPRIATE MEASURES TAKEN TO PREVENT BLOCKAGE CORRECT INSTALLATION IN ACCORDANCE WITH THIS SECTION WILL CONSIDERABLY MINIMISE THE LIKELIHOOD OF BLOCKAGEAND 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 EX CEPT 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 in plastic overflow pipe It is strongly recommended that this discharges internally into the household drainage system W here this is not possible discharge into an outside drain is perm
81. ther gas appliances in the property working Measure the Gas Rate 8 W ith any other appliances amp pilot lights turned O FF the gas rate can be measured It should be between 24 model 2 6m h 28 model 3 1m7 h 33 model 3 6 m h 9 The Calibration Function is active for 20 minutes unless the maximum CH temperature is exceeded 10 The function can be disabled at any time by turning the DHW temperature knob 11 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the boiler and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 12 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist 37 Time Pointer Constant Timed Fig 71a Rotate to adjust time On Position O ff Position Time Pointer Fig 71b 38 Baxi Heating UK Ltd 2012 11 0 Commissioning Setting the Timer NOTE If the integral timer is not required fit the blanking plate supplied in the installation kit The Electro Mechanical Timer allows the central heating system to be set every 15 minutes Using the three positio
82. tification Route Competent Person s Self Certification Scheme Install and Commission this appliance to manufacturer s instructions Complete the Benchmark Checklist If you notify via the Gas Safe 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 Baxi Heating UK Ltd 2012 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 4 IMPORTANT Installation Commissioning Service amp 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 amp Use Regulations Definition of
83. ts of existing plumbing must be considered If l soil pipes or waste pipes are subjected to internal pressure P N fluctuations when W C s are flushed or sinks emptied then surrounding surface Cut back pressure may force water out of the boiler trap and end at 45 cause appliance lockout Boiler iv Termination to a purpose made soakaway Further specific requirements for soakaway design are referred to in BS 6798 gt 500mm min Holes in the soak away must face away from the building 18 Baxi Heating UK Ltd 2012 v pumped into an internal discharge branch e g sink waste downstream of the trap end at 45 Basement or similar heated f Boiler Condensate Pump vi pumped into an external soil amp vent pipe Unheated Location e g Garage Basement or similar heated f Boiler Condensate Pump Baxi Heating UK Ltd 2012 7 0 Site Requirement Condensate Drain cont Pipe must terminate above water level but below surrounding surface C ut 12 A boiler discharge pump is available MULTIFIT part no 720648301 This pump will dispose of both condensate amp 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 H eating Elements are available in various lengths MULTIFIT part nos 1 metre 720644401 2 metre 720664101 3 metre 720
84. ure Sensor 48 Baxi Heating UK Ltd 2012 14 0 Changing Components Ze Plate Heat Exchanger Fig 98 1 Drain the boiler primary circuit and remove the gas valve as described in section 14 23 2 W hile supporting the heat exchanger undo the screws securing it to the brass manifolds 3 W ithdraw the heat exchanger upwards taking care not to damage any wires or controls Seals 4 There are four rubber seals between the manifolds and heat exchanger which may need replacement 5 Ease the seals out of the manifold Replace carefully ensuring that when the seal is inserted into the manifold it is parallel and pushed fully in 6 W hen fitting the new heat exchanger note that the left hand location stud is offset towards the centre more than the right hand one 7 Reassemble in reverse order Ale Diverter Valve Motor Unit amp Assembly Fig 99 1 To replace the motor unit disconnect the multi pin plug 2 Pull off the retaining clip and remove the motor unit 3 The motor unit can now be replaced or the valve assembly removed 4 Drain the primary circuit and draw off any hot water once the isolating taps are closed 5 Undo the nuts on the tap rail under the boiler Remove the screws securing the valve assembly to the boiler bottom panel and plate heat exchanger 6 Remove the valve assembly Examine any seals or washers replacing if necessary Transfer the DHW NT

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