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Baxi Potterton PERFORMA 30 HE User's Manual

1. easure and cut ensions tha exi are o size the concentric assembly and any being used nsert the concen ou ric assembly through the hole from side the building Fig 19 5 f required the flexible flue trim should be fitted prior to this as tt cannot be fitted after Use the large Jubilee clip to secure the trim to the flue See Fig 20 trim shown dot Flue Trim tted with the screw part of the clip at the bottom 6 Connect any extensions or elbows that are being used to he concentric assembly Engage the extension elbow or concentric assembly in the boiler flue elbow Fit the boiler flue elbow to the boiler adaptor nsure that the concentric assembly and any extensions Spigot back to the boiler at an angle of 3 and that the ernal air inlet is to the bottom Fig 20 wn 8 Use suitable brackets to support the concentric assembly and any extensions and make good inside and outside Position of Jubilee Clip M Screw 9 The 60 exhaust can now be fitted Slide the adaptor over the plain end of the 60 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 Adaptor shown in Fig 21 Secure the adaptor to the spigot using one of the screws supplied Fig 22 10 If it is necessary to shorten the 600 exhaust or an
2. 2A fuse bk bk Live brown Neutral blue Room Thermostat IMPORTANT If an integral timer is fitted to the boiler an external frost thermostat wired as shown will not operate correctly Only external timers may be used in such installations as in the diagram Terminal Block Fig 43 Functional Flow Diagram External Controls Selector Reset Switch Flue Thermostat Safety Overheat Thermostat r Central Heating r NTC Sensor g DHW NTC Sensor bk Gas Valve Modulator C Spark Electrode Key to Wiring Gas Valve b blue br brown Condensate Trap bk black 1 Flame Sensing Electrode red g green Hydraulic Differential Pressure Switch DHW Flow Priority Microswitch Fig 44 Baxi Heating UK Ltd 2007 10 0 Installation Making The Electrical Connections To connect the mains input cable proceed as follows Slacken the facia securing screws and lift the outercase panel so that its locating tabs are clear of the facia Remove the panel 2 Completely undo the screws securing the facia panel and hinge it down Fig 40 3 Remove the control box cover securing screws Disengage the barbs on the control box from the cover Remove the cover Fig 41 4 Slacken the cable clamp on the LH side of the boiler chassis Fig 42 Insert the cable through the clamp and route it to the terminal block 5 Slacken the screws in the te
3. d NC AD 7 Plastic Disc Fig 83 44 Baxi Heating UK Ltd 2007 14 0 Changing Components Plate Heat Exchanger Fig 67 Drain the primary circuit 2 While supporting the heat exchanger undo the screws securing to the brass manifolds 3 Withdraw the heat exchanger upwards and to the left of the gas valve 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 the seal is inserted into the manifold parallel and pushed fully in 6 When fitting the new heat exchanger note that the left hand location stud is offset towards the centre more than the right hand one 7 Reassemble in reverse order Diverter Valve Assembly Figs 82 amp 83 The diverter valve assembly comprises of a central heating pressure differential valve and a domestic hot water pressure differential valve These are connected to a manifold which is joined to the plate heat exchanger DHW Pressure Differential Valve Fig 83 Drain the primary circuit 2 Undo the screw securing the microswitch bracket to the valve Fig 82 3 Disconnect the two sensing pipes and slacken the grub screws securing the valve to the diverter manifold 4 Draw the valve away from the diverter manifold The valve
4. 5 Hand over the Users Operating Installation and Servicing Instructions giving advice on the necessity of regular servicing Fig 53 Fan Wires Sensing i Tubes Fan Spigot Outlet Pipe S Ease Fan Spigot Outlet Pipe Clamps Inwards 13 0 Servicing the Boiler Case Front Panel Annual Servicing For reasons of safety and economy it is recommended that the boiler is serviced annually Servicing must be performed by a competent person 2 After servicing complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication 3 Ensure that the boiler is cool 4 Ensure that both the gas and electrical supplies to the boiler are isolated 5 Slacken the screws securing the facia panel Lift the outercase panel so that its securing tabs are clear of the facia Remove the panel Fig 53 6 Remove the screws securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case Fig 54 Facia Panel Securing Screws 7 Note the positions of the two sensing tubes on the fan spigot and three wires on the fan motor and Fan remove them Fig 55 8 Slacken the screws on the fan spigot outlet pipe clamps Ease the clamps inwards over the pipe 9 Draw the outlet pipe away from the boiler 10 Remove the four screws securing the combustion
5. Example Not Permissible 0 1 2 If for instance a concentric length of 1 25 metres was Concentric 60 100 Flue metres Concentric 60 100 Flue metres required and the 60 exhaust needed to be metres the Example Example 2 graph shows that this combination would NOT be Flue Lengths Not Permissible Flue Lengths OK permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths OK Where both lengths have been determined they can be applied to the graph to check that the installation is permissible For example if tt was known that 0 5 metres of concentric flue and metre 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 60 Exhaust metres Example 3 Flue Lengths OK In the example shown assume that the concentric part of the flue needs to be metres long Find the position of I on the horizontal axis of the graph and then project upwards to the solid diagonal line This is represented by the vertical thick dotted line Where this dotted line intersects with the solid diagonal line on the graph project across to the vertical Concentric 60 100 Flue metres Example 3 axis As can be seen this corresponds with metres Flue Lengths OK P Therefore the total equivalent l
6. Gas Valve 2 Set the temperature controls to maximum and the selector switch to the Off position Fig 51 3 Slacken the pressure test point sealing screw on the gas valve and connect a pressure gauge Fig 48 4 Undo the screws securing the inner door panel Lift Fig 48 the panel slightly to disengage it from the studs on top of the case Plastic 5 Turn the selector switch fully anticlockwise against the Protection Si Ca spring pressure to the reset position and hold for 2 seconds to reset the boiler Fig 51 6 Turn the selector switch to the Cental Heating and Domestic Hot Water position W The power On neon Q will illuminate Fig 51 Modulator e rig 51 Wire Maximum Rate i 7 Turn a hot water tap on to give a flow rate of at least Adjustment Nut Minimum Rate O0l min Adjustment Nut 8 The pressure should be Fig 49 NOTE Gas Valve Electrical Plug Igniter not shown for clarity NG iZ imbar Propane 32 3mbar If not check that the gas supply pressure is correct Natural Gas 20mbar and Propane 37mbar 9 The pressure can be adjusted if required 10 To check and set minimum pressure first remove one of the modulator wires Selector Switch Pressure Gauge Adjusting the Pressure Fig 49 Fig 50 Remove the plastic protection cap from the d pressure adjustment nuts on the valve 2 The smaller nut 5mm adjusts minimu
7. YES YES neon flashing Go to section B neon flashing Go to section C Turn selector to reset position If regular resetting is required or appliance still Go to sections J amp NO does not operate investigation Is necessary ME neons flashing Go to section D NO Air pressure switch proved E YES Turn the selector to the reset Spark at ignition electrodes YES position If the light does not for up to 10 seconds neon fashing extinguish go to section H amp NO K YES Replace PCB NO Burner on 4 neon to section F illuminated YES Burner extinguishes YES neon flashing after 10 seconds Go to sections I amp L NO Reduce the DHW flow rate If burner does not modulate clean DHW temperature sensor and DHW heat Burner output modulates to maintain temperature set at thermostat YES Close DHW tap YES exchanger If modulation does not occur go to section DHW flow valve senses no flow Primary water diverted to Diverter valve spindle CH system DHW flow assembly faulty switch released off YES NO YES YES Baxi Heating UK Ltd 2007 49 16 0 Fault Finding Fault Finding Solutions Sections A to E A Is there 230V at Main terminals L and N ne NO 3 Selector terminals a amp b and a amp 3 PCB A4 connector Check electrical supply Replace fuse neon Replace PCB illuminat
8. an adjacent opening window vertical only 1000 n addition the terminal should be no nearer than 150 mm to an opening in the building fabric formed for the purpose of accommodating a built in element such as a window frame See BS 5440 Pt 1 NOTE The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below 300 min L Terminal Assembly Top View Rear Flue Fig 12 Property Boundary Line Air Inlet 1 1 1 1 1 i Plume i Displacement Kit i 1 1 1 1 1 1 1 7 0 Site Requirements Flue NOTE Due to the nature of the boiler a plume of water vapour will be discharged from the flue This should be taken into account when siting the flue terminal The following guidelines indicate the general requirements for siting balanced flue terminals For GB recommendations are given in BS 5440 Pt For IE recommendations are given in the current edition of I S 813 Domestic Gas Installations 2 If the terminal discharges onto a pathway or passageway check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway 3 If a terminal is less than 2 metres above a balcony above ground or above a flat roof to which people have access then a suitable
9. and carefully remove the four screws The diaphragm spring will force the two halves of the valve apart 8 Carefully examine the diaphragm and replace it if there is any damage 9 Reassemble in reverse order CH Pressure Microswitch Fig 84 Remove the two wires from the Pressure microswitch 2 Undo the screw securing the microswitch bracket to the valve body 3 Reassemble in reverse order Cartridge Flow Regulator Figs 85 amp 86 Body Filter Gauze Undo the filter cartridge from the inlet return Flow e Regulator E M Venturi manifold Fig 85 2 Unscrew the venturi and remove the flow regulator Fig 86 3 Check the cleanliness of the filter gauze rinsing thoroughly in clean water as necessary Fit the new flow regulator and reassemble in reverse order Inlet Return Manifold Baxi Heating UK Ltd 2007 45 Secondary Heat Exchanger Pipe Connecting Clip Fan Spigot Outlet Pipe Clamp Outer Drum Boiler Return Pipe Heat Exchanger Return Pipe Fan Spigot Outlet Pipe Ease Fan Spigot Outlet Pipe Clamps Inwards Fig 88 Fan Spigot Outlet Pipe Overheat Thermostat 46 Baxi Heating UK Ltd 2007 14 0 Changing Components Secondary Heat Exchanger Fig 87 Drain the primary circuit 2 Undo the four screws securing the right hand case panel Remove the pan
10. are completed successfully the flue overheat thermostat may have operated Press the reset button on the flue overheat thermostat If the boiler does not relight or repeatedly cuts out Check the operation of the flue system or replace the flue overheat thermostat 52 Baxi Heating UK Ltd 2007 17 0 Short Parts List Short Parts List Key GC Description Manufacturers No No Part No 44 22 Fan 5112430 M 23 Pressure Switch 248466 32 Heat Exchanger 5112431 41 Burner 5112770 131 CF 135 44 njector 5112376 63 59 E66 408 Electrode Lead 248037 63 E66 411 Spark or Sensing Electrode 247384 72 Pump 248042 01 66 432 3 Way Valve Assy 24806 3l 342 571 Temperature Sensor 247394 35 E66 439 Safety Thermostat 248079 40 Gas Valve 5107339 54 PCB 5112380 69 E66 453 Pressure Gauge 248090 327 gniter Gas Valve Cable 5112385 A Flue Overheat Thermostat 5112395 59 a 7777 Lis Lin Ui yi Ly H Ay Mir jj DPR ST LNT LIT Myc d D i ii Lira Y yp 779 7777 gt Ly Ly Ly Uy lt L ii L L yin gy 32 169 Baxi Heating UK Ltd 2007 53 BENCHMARK No 511111118 1 5 C benchmar J GAS BOILER COMMISSIONING CHECKLIST COLLECTIVE MARK BOILER SERIAL No N
11. box door and remove the door Fig 54 Fig 55 S Combustion 4 Box Door Fig 54 Inner Door Panel Baxi Heating UK Ltd 2007 35 Tab Spring Clip 2e Fan and Hood Assembly Fig 57 Electrode Grommets 5 Fig 58 f Threaded Fig 59 7 Bush Cartridge Body Filter Gauze Blanking Cap Cold Water X Inlet Tap Flow Regulator Venturi Fig 60 Inlet Return Manifold 36 Q Baxi Heating UK Ltd 2007 13 0 Servicing the Boiler Annual Servicing Cont Ease the front edge of the left hand baffle upwards disengaging the spring clip Disengage the tab on the baffle from the slot in the fan hood Fig 56 12 Undo the screws securing the fan and hood to the appliance back panel Draw the assembly forwards Fig 57 13 Undo the screws securing the burner to the injector manifold Draw the burner out of the combustion box pulling the electrode grommets from the slots in the combustion box lower panel Fig 58 4 Disconnect the electrode leads and grommets from the electrodes Completely remove the burner Fig 58 5 Brush any deposits from the injectors Do not use a pin or wire to clean them 6 Brush the burner blades and venturis and clean the combustion box 7 Ensure that the heat exchanger fins are clear of any obstruction NOTE If necessary the secondary heat exchang
12. efficient operation of the expansion vessel which is required to accommodate the thermal expansion of the water 4 When the domestic water system includes any device which prevents water expanding back towards the supply check valve loose jumpered stopcock water meter water treatment device then an expansion vessel must be fitted eg Zilmet 60ml R 5bar 5 If the hot water expansion is not provided for then hi fittings and devices on the system gh pressures can develop which may result in damage 6 The boiler s maximum working mains pressure is 8 bar herefore all pipework connections fittings etc should be suitable for pressures in excess of 8 bar A pressure reducing valve must be fitted for pressures in excess of 8 bar The manufacturer of any outlet fittings such as a shower valve may require a lower maximum pressure The pressure reduction must take account of all fittings connected to the DHW system mq Showers 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 Water Areas If the area of the installation is recognised as a HARD WATER AREA then a suitable device should be fitted to treat t
13. for routine maintenance However a 15 x 1 25 Diameter clearance of 20mm is required if it is necessary to Primary Water Content 12 Electrical Suppl 230V 50H remove the secondary heat exchanger This of Boiler unpressurised Appli PPY i idi 2 should be considered when siting the appliance Appliance must be conngciedto an and in the event of any subsequent alterations in earthed supply Temperatures the area of installation C H Flow Temp adjustable Power Consumption 180W 35 C to 85 C 5 C Weights kg External Fuse Rating 3A p D H W Flow Temp adjustable 35 C to 65 C max 5 C Internal Fuse Rating dependent upon flow rate Fuse 2A Fast Blow to BS 4265 Pump Available Head SEDBUK Declaration For Performa 30 HE The seasonal efficiency SEDBUK is 87 3 89 4 LPG Band B This value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by 0051 LPG Propane G31 Metre wg Burner Injector 15 x 0 77mm diameter Burner Pressure Max Rate Min Rate Propane mbar 32 3 05 52 02 Inlet Pressures mbar 0 200 400 600 800 1000 1200 Flow Rate l h Baxi Heating UK Ltd 2007 9 1 5 to 3 Tube 100mm Tap Rail 5 0 Dimensions and Fixings Heating Flow 22mm li IO Baxi Heating UK Ltd 2007 65 mm 65
14. may now be replaced or split to examine the diaphragm 5 To examine the diaphragm hold the valve body securely and carefully remove the six screws The diaphragm spring will force apart the two halves of the valve 6 Remove the plastic disc and pushrod assembly Carefully examine the diaphragm and replace it if there is any damage 7 Reassemble in reverse order Central Heating Pressure 14 0 Changing Components Differential Valve Microswitch Bracket Diverter Valve Assembly Cont Sensing Pipe R Pressure Differential Valve Fig 84 Remove the pressure differential valve as described above By pass Pipe Diaphragm p 2 From the brass diverter manifold undo the nut on 1 the heating flow pipe Remove the screw securing the diverter manifold to the appliance lower bracket 3 Disconnect the pressure gauge capillary from the Heating Flow Pipe diverter manifold and remove the two wires from the microswitch 4 Prise off the spring clip securing the by pass pipe to the diverter manifold and disconnect the sensing pipe Diverter Manifold 5 Ease the diverter manifold out of the plate heat i 3 exchanger manifold Remove the assembly from the Fig 84 Pressure Gauge appliance Capillary 6 Undo the screw securing the microswitch bracket to the valve body The sensor may now be dismantled to examine the diaphragm 7 To examine the diaphragm hold the assembly securely
15. mm Domestic Hot Water Outlet 15mm Inlet 22mm 60 ta E 1 li 1 1 1 1 lt 28mm Condensate 1 li Drai 65 mm 65 mm 65 mm TN Cold Water Heating Pressure Relief Inlet Return Valve 15mm 22mm 15mm P4 Baxi Heating UK Ltd 2007 6 0 System Details mE Information The Baxi Combi 105 HE Condensing Combination Boiler is Water Byelaws Scheme Approved Products To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes IRN a IRN OOI See text of entry for installation requirements and notes b IRN 302 Byelaw 14 2 Reference to the WRc publications Water fittings and materials directory and Water supply byelaws guide give full details of byelaws and the IRNs Central Heating Circuit The appliance is suitable for fully pumped SEALED SYSTEMS ONLY Treatment of Water Circulating Systems All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system risking damage to pump and valves boiler noise and circulation problems When fitting new systems flux will be evident within the system which can lead to damage of system components All systems must be thoroughly drained and f
16. seal supplied Ensure the discharge of condensate complies with any national or local regulations in force see British Gas Guidance Notes for the Installation of Domestic Gas Condensing Boilers 2 The condensate outlet terminates in a BSP nut and seal for the connection of 21 5mm 4in plastic overflow pipe which should generally discharge internally into the household drainage system If this is not possible discharge into an outside drain is acceptable 10 0 Installation Fitting The Flue HORIZONTAL FLUE 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 34 2 Locate the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 35 NOTE The flue elbow is angled at 91 5 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 36 4 To dimension X add 50mm This dimension to be known as Y Wall Thickness Flue Elbow IMPORTANT Check all dimensions before cutting Fig 35 Wall Thickness Fig 36 Baxi Heating UK Ltd 2007 29 Waste Fig 37 30 Q Baxi Heating UK Ltd 2007 Flue Fig 39 10
17. settings of the temperature control knobs Rotate the knobs 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 79 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 and turn them fully anticlockwise 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions Selector Switch Fig 80 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 79 3 Note the position of the electrical connections and the orientation of the switch Remove the electrical connections 4 Remove the screws securing the switch to the facia panel 5 Fit the new switch ensuring that it is correctly positioned and reassemble in reverse order 43 Plate Heat Exchanger Rubber Seal Om Fig 81 Sensing Pipes Microswitch Bracket DHW Pressure Fig 82 i Differential Valve Diaphragm Diaphragm Spring
18. truck or other suitable trolley Always grip the boiler firmly and before lifting feel where the weight is concentrated to establish the centre of gravity repositioning yourself as necessary See the Installation section of these instructions for recommended lift points Remember The circumstances of each installation are different Always asses the risks associated with handling and lifting according to the individual conditions If at any time when installing the boiler you feel that you may have injured yourself STOP DO NOT work through the pain you may cause further injury IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING Baxi Heating UK Ltd 2007 5 6 Control Box Fig Baxi Heating UK Ltd 2007 Front Panel CA Data Badge 1 0 Introduction 11 Description The Potterton Performa 30 HE 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 31 0 kW condensing 3 It is designed for use on Natural Gas G20 and can be converted to use Propane 4 The boiler is suitable for use only on fully pumped sealed heating systems Priority is given to domestic hot water 5 The boiler data badge gives details of the
19. 0 Installation Fitting the Flue Cont 5 Mark dimension Y on the flue as shown Fig 37 Carefully cut the waste material from the flue ensuring that the ducts are square and free from burrs 6 The inner flue duct support bracket may be in the waste portion of the flue In this case retrieve the bracket before discarding the waste 7 Take the inner flue support bracket if not already fitted and engage it over the flue duct This will centralise the flue and air ducts and ease assembly Fig 38 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 39 10 Make good between the wall and air duct outside the building Fit the flue trim if required and if necessary fit a terminal guard see Section 8 8 amp 8 9 VERTICAL FLUE Only a flue approved with the Potterton Performa 30 HE can be used N For information on vertical flues consult the Potterton mn ue Guide brochure Control Box Cover Fig 41 Fig 42 5 Cable Clamp Facia Panel Frost Thermostat Fuse L o br i n o OF External Clock E 9 Fused supply Always fit fast 9 230V 50Hz
20. 2007 6 0 System Details System Filling and Pressurising I A filling point connection on the central heating return pipework must be provided to facilitate initial filing and pressurising and also any subsequent water loss replacement refilling 2 There are connection points on the mains cold water inlet and central heating return isolating taps Fig 5 to which the optional filling loop kit Part No 248221 can be assembled 3 The filing method adopted must be in accordance with all relevant water supply regulations and use approved equipment 4 Your attention is drawn to for GB guidance G24 2 and recommendation R24 2 of the Water Regulations Guide for IE the current edition of I S 813 Domestic Gas Installations 5 The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe provided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use 16 6 Expansion Vessel Central Heating only The appliance expansion vessel is pre charged to 0 5 bar Therefore the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres For greater system capacities an additional expansion vessel must be fitted For GB re
21. Failure or Blocked Condensate Drain 25 Safety Thermostat Activated Boiler or Flue 26 Fault on Fan or Flue 27 Fault on Pump or Low System Pressure 28 Fault on Hot Water Sensor 29 Fault on Central Heating Sensor 30 Power On 3l Domestic Hot Water Mode 32 Central Heating Mode 33 Burner On When neons 24 to 29 are constantly illuminated they indicate the temperature of the central heating water We E 30 40 50 60 70 80 a AS Oe A A 21 22 23 Baxi Heating UK Ltd 2007 Central Heating Circuit 28 23 22 16 Fig 2 Key Primary Heat Exchanger 15 Domestic Hot Water Outlet 2 Burner 16 Heating Flow 3 lgnition Electrode 17 Pressure Gauge 4 Flame Sensing Electrode 18 Hydraulic Differential Pressure Sensor Microswitch 5 Gas Valve 19 Automatic By Pass 6 Pump 20 Hydraulic Differential Pressure Sensor 7 Automatic Air Vent 21 Diverter Valve Assembly 8 Plate Heat Exchanger 22 Domestic Hot Water Flow Priority Assembly 9 Flow Sensor with Filter 23 Domestic Hot Water Flow Priority Microswitch IO Pressure Relief Valve 24 Safety Thermostat Boiler Drain Point 25 Central Heating Temperature Sensor 12 Heating Return 26 Expansion Vessel 13 Cold Water Inlet On Off Valve and Filter 27 Domestic Hot Water Temperature Sensor 14 Gas Inlet 28 Secondary Heat Exchanger Domestic Hot Water Circuit 28 23 22 Fig 3 8 Q Baxi Heating
22. Installation amp Service Instructions Performa 30 HE These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Baxi Heating UK Ltd 2007 Natural Gas Potterton Performa 30 HE G C N 47 393 13 Building Regulations and the Benchmark Commissioning Checklist Building Regulations England amp Wales require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department From 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 January 2006 operate a Self Certification Scheme for gas heating appliances These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook which was then left on site with the customer With the introduction of Self Certification Schemes the Benchmark Logbook is being withdrawn However a similar document in the form of a commissioning checklist and service interval record is incorporated at the back of these instructions Potterton 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 ce
23. L No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 5 DATE SERVICE 6 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 7 DATE SERVICE 8 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 9 DATE SERVICE 10 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE 55 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 Brooks House Coventry Road Warwick CV34 4LL After Sales Service 08706 017 017 Technical Enquiries 08706 049 049 Website www potterton co uk e amp oe A BAXI GRGUP company Baxi Heating UK Ltd 2007 Comp N 5111815 Iss 4 1 07
24. OTIFICATION No CONTROLS To comply with the Building Regulations each section must have a tick in one or other of the boxes TIME amp TEMPERATURE CONTROL TO HEATING ROOM T STAT amp PROGRAMMER TIMER PROGRAMMABLE ROOMSTAT TIME amp TEMPERATURE CONTROL TO HOT WATER CYLINDER T STAT amp PROGRAMMER TIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED L HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE BURNER OPERATING PRESSURE IF APPLICABLE CENTRAL HEATING FLOW TEMPERATURE CENTRAL HEATING RETURN TEMPERATURE FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED YES WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE amp RECORD GAS RATE MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE HOT WATER OUTLET TEMPERATURE pu WATER FLOW RATE Itsimin FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INS
25. Operating 25 Flue Terminal Di l00 Min Operating 0 5 kW 30 5 119 M Recommend Operating 1 2 Dimensions Projection 125mm Heat Output CH Non Condensing DHW Circuit bar Max Min Pressures B jr i Connections copper tails ax Operating 8 Pus apie ino FI in Operating 0 2 Heat Output CH Condensing roe Sang 7 enna eating Em i in Operating Pressure Cold Water Mains Inlet 5mm t132 l mi 096 kw 31 113 ee DHW Flow 5mm Heat Input DHW Pressure Relief Discharge 5mm doris l min Max Outercase Dimensions 30 C Rise 14 1 kW 30 5 Casing Height 780mm DHW Flow Rate Overall Height Inc Flue Heat Output DHW Elbow 965mm 35 C Rise 12 1 Pa Casing Width 450mm in Working kw 29 6 Casing Depth 345mm DHW Flow Rate 25 Max Gas Rate Natural Gas G20 i Available H S h bel s h ug 0 Above Casing 200 mm Min clar ENTE Below Casing 200 mm Min Expansion Vessel For Central Heating Burner Pressure Natural Gas G20 Front 450 mm Min For Servicing only Integral with appliance Max Rate Min Rate Front 5 mm Min Operation bar mbar 121 05 2 1402 LH Side 5 mm Min Min Pre charge Pressure 0 5 RH Side 5 mm Min In Operation Inlet Pressure Natural Gas G20 20mm Min See Note iire mbar 20 NOTE The boiler can be operated with a Max Capacity of clearance of 5mm at the right This is also CH System 125 Burner Injector Natural Gas G20 sufficient
26. TALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS IF REQUIRED BY THE MANUFACTURER HAVE YOU RECORDED A CO CO2 RATIO READING N A YES CO CO RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER COMMISSIONING ENG S NAME PRINT CORGI ID No 54 SIGN DATE SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the boiler manufacturer s instructions Always use the manufacturer s specified spare part when replacing all controls SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 3 DATE SERVICE 4 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TE
27. UK Ltd 2007 3 0 Appliance Operation NOTE All delay timers mentioned in 3 1 and 3 2 are overridden by domestic hot water demand Central Heating Mode Fig 2 With a demand for heating the pump circulates water through the primary circuit At a pre determined flow rate the central heating flow switch operates initiating the ignition sequence 2 The main bumer ignites at low rate then the gas valve controls the gas rate to maintain the heating temperature measured by the temperature sensor 3 When the flow temperature exceeds the setting temperature a 3 minute delay occurs before the burner relights automatically anti cycling The pump continues to run during this period 4 When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes Pump Overrun Domestic Hot Water Mode Fig 3 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 DHW flow switch which requests the 3 way valve to change position This will allow the pump to circulate the primary water hrough the DHW plate heat exchanger 3 The burner will light automatically and the emperature of the domestic hot water is controlled by he temperature sensor 4 When the domestic hot water demand ceases the burner will extinguish and the diverter valve will remain in the domestic hot w
28. ater mode unless there is a demand for central heating IMPORTANT When the selector switch is in the 0 Off position the electrical supply to the boiler is isolated The boiler will not operate and the integral timer if fitted will require resetting once the selector switch is set to either Position i or Position ii Frost Protection Mode The frost protection mode is integral to the appliance and functions only with the selector switch see Section 2 1 in the domestic hot water and central heating position If the system temperature falls below 5 C then the boiler will fire on its minimum setting until a flow temperature of 30 C is reached Further protection can be incorporated by using a system frost thermostat Pump Protection 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 minute in every 24 hours to prevent sticking 4 0 Technical Data Performa 30 HE Appliance Type Cy Cs Electrical Protection IPX5D Central Heating Primary Circuit Pressures Appliance Category CAT Il 2H NO Class 3 Heat Input CH Safety Discharge 3 m Condensate Drain BSP Max
29. aust TU Flue Pipe 600 Support Bracket O Rin rr LJ Flexible Flue a5 Trim Adaptor 5 Jubilee Clip Ring O py 60 100 Concentric Flue Fig 14b Outlet must be at least 45 from wall face Peak Uppermost 500mm Min Air Inlet at Bottom Fig 16 Baxi Heating UK Ltd 2007 9 0 Plume Displacement EN Plume Displacement Kit Fig 14b Kit No 5117379 or 5118638 incl boiler elbow Content of kit 0 9m 60 100 Concentric Flue Im 60 Dia Exhaust Flue Pipe Adaptor 2 60 Dia Support Brackets 93 Elbow Plume Outlet Assembly Flexible Flue Trim Rings Jubilee Clip Boiler Elbow 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 Ww ith the peak uppermost to prevent rain entry Figs 15 amp 16 and be at least 2 metres above ground level It must be secured as shown in Fig 12a The plume outlet must also be at least 500mm from the air inlet in any direction Fig 16 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
30. ber issued by CORGI is written onto the Benchmark Checklist CORGII will record the data and will send a certificate of compliance to the property Baxi Heating UK Ltd 2007 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 competence A person who works for a CORGI 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 1 5 813 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 Warnin
31. circuit and remove the socket head screws securing the pump head to the body and draw the head away 2 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 3 A standard Grundfos 15 60 replacement head can now be fitted Connect the wiring to the new head The pump speed must be set to 3 Fig 72 4 Reassemble in reverse order RAEE Pump Complete Fig 73 P Wiri Drain the primary circuit and unscrew the automatic ump Wirin Jae 8 air vent from the pump body Undo the two screws securing the body to the pipe and manifold and draw the pump forwards 2 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position Socket Headed gt I Screw 3 Connect the wiring to the new pump Examine the O ring seals on the return pipe and manifold replacing 3 if necessary Pump Head 4 Fit the air vent to the pump body and reassemble in Fig 71 reverse order RAES Automatic Air Vent Fig 73 Drain the primary circuit and unscrew the automatic air vent from the pump body Pump Setting i Automatic Air i 2 Examine the O ring seal replacing if necessary and Vent Fig 72 fit it to the new a
32. crews securing the electrodes to the burner Examine the condition of the electrodes replacing if necessary Fit the electrodes to the new burner 5 Engage the burner location brackets over the studs on he injector manifold and reassemble in reverse order 14 0 Changing Components Injectors Fig 66 Remove the burner as described in Section 4 4 Injector Manifold Inlet Elbow 2 Undo the screws securing the injector manifold to Gasket the inlet elbow and remove the manifold 3 Unscrew and replace injectors as required and examine the sealing gasket replacing as necessary Reassemble in reverse order Electrodes Fig 66 Electrodes Remove the four screws securing the combustion box door and remove the door Electrode Grommets 2 Undo the screws securing the burner to the injector manifold Draw the burner out of the Elected combustion box pulling the electrode grommets from Leads the slots in the combustion box lower panel 3 Disconnect the lead and grommet from the electrode being replaced Undo the securing screw and withdraw the electrode to the burner 4 Reassemble in reverse order ESAME Insulation Fig 67 Remove the four screws securing the combustion box door and remove the door 2 Slide the side insulation pieces carefully out of their carriers 3 To replace the rear insulation piece it is neces
33. ed Check wiring Replace selector terminals 4 8 5 B Is there 230V at l If pump jammed release Replace pump PCB A4 connector terminals 3 amp 6 YES Change pump supply cable Replace PCB CH system pressure 0 5 to 1 5 bar Re pressurise system 2 NO Ls Check the tap of the automatic air Open the automatic air vent vent is opened Primary flow valve diaphragm damaged IS NO Replace diaphragm Flow valve rod obstructed D Continuity across flow microswitch and PCB A5 connector terminals 7 amp 8 Replace microswitch 2 Primary temperature sensor faulty YES Cold resistance approx K ohms resistance reduces with increase in temp Replace sensor Fan connections correct at fan PCB A2 connector is 230V across terminals 5 amp 7 YES Fan jammed or faulty winding Replace fan Replace PCB 50 Q Baxi Heating UK Ltd 2007 16 0 Fault Finding E Check and correct if necessary Electrical and pressure tube connections Replace air pressure 2 Blockage of pressure tubes switch 3 Restriction in flue 4 Venturi F n Ensure gas is on and purged PCB Al connector has 230V AC across terminals 2 amp 4 NO neon flashing NO Replace PCB Replace gas valve Turn selector switch to Reset position Check the burner setting pressure of the gas valve see Section 9 2 of Commissioning 2 Voltage a
34. el 3 Prise the connecting clips from the heat exchanger return pipe and the boiler return pipe Remove the pipes 4 Slacken the screws on the left hand fan spigot outlet pipe clamp Ease the clamp to the right 5 Remove the nut securing the elbow to the secondary heat exchanger Draw the elbow and outlet pipe forwards 6 Remove the secondary heat exchanger from the outer drum by easing it forward 7 Reassemble in reverse order of dismantling IPM Flue Overheat Thermostat Fig 88 NOTE The flue overheat thermostat includes a reset button Check that the thermostat will not reset before replacing Remove the fan spigot outlet pipe from the fan and elbow 2 Pull the two wires off the terminals on the flue overheat thermostat Unscrew the thermostat from the adaptor in the outlet elbow 3 Reassemble in reverse order of dismantling 15 0 Illustrated Wiring Diagram Air Pressure Switch Central Heating Temperature Sensor Domestic Hot Water Temperature Sensor Domestic Hot Water Flow Priority Pressure Switch Hydraulic Differential Pressure Switch CONMOMAWNM Control PCB Electrode b b r br bk b Overheat Stat g y ON Gas Valve 2 Condensate Trap br brown bk black b d Optional Timers r re g green g y green yellow w white Baxi Heating UK Ltd 2007 47 16 0 Fault Finding Carry out initial fau
35. ength of the 600 exhaust can be up to metres Any bend equivalencies must be accounted for i e 93 bends are equal to metre each 45 bend to 0 5 metres 600 Exhaust Support Bracket Flue Length Worked Example Potterton Performa 30 HE 93 Elbow In Fig 18 opposite an additional 93 bend has been included in the 602 exhaust with 2 x metre extensions which have Concentric 60 100 Flue been cut to 0 25metres and fitted The waste is discarded To calculate total length Fig 17 2 x 025 metre Lengths 0 5 metres x 93 Elbow metre Total 60 Exhaust 1 5 metres After consulting the table in Example 3 it can be determined Additional Accessories that the concentric flue could be up to approximately 0 5 metres long A 93 Elbow 5117381 B 45 Elbow Pair 5117382 C metre 60 Extension 5117380 24 Baxi Heating UK Ltd 2007 9 0 Plume Displacement General Fitting Notes 000 000 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 he boiler at an angle of 3 Min 2 metres 2 When completed above ground evel the terminal must be at least 2 metres Fig 19
36. er may be dismantled see section 14 24 DHW Filters Fig 60 18 If the flow of domestic hot water is diminished it may be necessary to clean the filters 19 Initially check the cold water inlet tap filter 20 Turn the tap off Undo the blanking cap and remove the thread bush Fig 59 21 Extract the filter and rinse thoroughly in clean water Reassemble and check the flow If required clean the manifold filter as described below 22 Undo the filter cartridge from the inlet return manifold 23 Dismantle the cartridge and carefully remove the flow regulator and filter gauze Rinse them thoroughly in clean water and reassemble in reverse order 24 Check that the pressure vessel charge is 0 5bar and reassemble in reverse order of dismantling and recommission 25 Turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 2 seconds to reset the boiler 26 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 Pressure Switch Sensing Tubes Fig 61 Pressure Switch Wires Fan Wires Fan wv V Sensing Tubes Ease Fan Spigot Outlet Pipe Clamps Inwards gt e i Fig 62 Fan Spigot Outlet Pipe Baffle i _Tab Spring Clip Fig 63 ae p lt y 9 Spring Washer 220 E pring ra Sec
37. eviously removed secure the inlet adaptor to the top panel 6 Continue to fit the twin flue system Position of Restrictor 21 amount off the Air Duct amp Flue Duct Cut the same 1425mm Air Duct Flue Duct __ p Push Fit Adaptor NS 22 Q Baxi Heating UK Ltd 2007 Flue Deflector 8 0 Flue Options EG For Roof Terminals In the case of a pitched roof 25 50 degrees position the lead tile to replace flash over existing roof tiling Make an aperture in the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained The adjustable plastic collar can either be positioned on the lead tile or the lower tube of the roof terminal prior to the final positioning of the vertical flue through the tile Check the collar is correctly located to suit required roof pitch either 25 to 38 or 37 to 50 From inside the roof adjust the flue to a vertical position and secure to the roof structure with the clamp supplied 2 For flat roof installations the aluminium flashing must be incorporated into the roof covering and the appropriate aperture made in the roof decking The vertical flue is lowered onto the flashing making sure the collar of the flue locates securely with the flas
38. fer to BS 7074 Pt For IE the current edition of 1 5 813 Domestic Gas Installations Pressure Relief Valve Fig 6 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable for pressures in excess of 3 bar 2 The pressure relief discharge pipe should be not less than 5mm dia run continuously downward and discharge outside the building preferably over a drain It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components The end of the pipe should terminate facing down and towards the wall 3 The discharge must not be above a window entrance or other public access Consideration must be given to the possibility that boiling water steam could discharge from the pipe Fig 7 Other Tap Outlets Expansion Vessel 7 Pressure Reducer Taps Baxi Heating UK Ltd 2007 6 0 System Details EN Domestic Hot Water Circuit Fig 7 All DHW circuits connections fittings etc should be fully in accordance with relevant standards and water supply regulations 2 Your attention is drawn to for GB Guidance G17 to G24 and recommendation R17 o R24 of the Water Regulations Guide for IE the current edition of I S 813 domestic Gas nstallations 3 A single check valve must be fitted as shown in Fig 7 prevent backflow to the supply pipe and to ensure the
39. g Check the information on the data plate is compatible with local supply conditions All CORGI registered installers carry a CORGI identification card and have a registration number You can check your installer is registered by telephoning 0870 4012300 or writing to Elmwood Chineham Business Park Crockford Lane Basingstoke RG24 8WG or check online at www corgi gas safety com The boiler meets the requirements of Statutory Instrument The Boiler Efficiency Regulations 1993 Ne 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 iquid or gaseous fuels Type test for purpose of Regulation 5 certified by otified Body 0051 Product Production certified by otified Body 0086 For GB IE only Baxi Heating UK Ltd 2007 Legislation This company declare that no substances harmful to health are contained in the appliance or used during appliance manufacture The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force and only used in a suitably ventilated location In GB the installation must be carried out by a CORGI Registered Installer It must be carried out in accordance with the relevant requirements of the Gas Safety Installation amp Use Regulations The appropriate Building Regulations either The uilding Regulations The Building Reg
40. he mains water supply to the boiler Contact your Water Distribution Company for advice on suitable devices 5mm Min 450mm gt gt gt Fig 8 p Min greca Servicing Purposes te Min In a Fig 9 14 Baxi Heating UK Ltd 2007 20mm 5mm Min See NOTE 200mm Min E 780mm y 200mm Min y 7 0 Site Requirements Location The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i e garage or outhouse The boiler may be fitted inside a cupboard see Section 7 3 2 If the boiler is sited in an unheated enclosure then it is recommended to leave the ON OFF Selector Switch in the domestic hot water and central heating position to give frost protection 3 If the boiler is fitted in a room containing a bath or shower reference must be made to the relevant requirements In GB this is the current I E E Wiring Regulations and Building Regulations In IE reference should be made to the current edition of LS 813 Domestic Gas Installations and the current ETCI rules 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the curre
41. hing 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 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 685mm from elbow to terminal Fig 13 The maximum permissible equivalent flue length is 3 metres NOTE Each additional 45 of flue bend will account for an equivalent flue length of 0 5m eg 45 0 5m 90 2 x 45 Im etc Flue Trim The rubber flue trim supplied may be fitted to either the outside wall or on the inner wall of installation Terminal Guard Fig 14 When codes of practice dictate the use of terminal guards they can be obtained from most Plumbers and Builders Merchants 2 There must be a clearance of at least 50mm between any part of the terminal and the guard 3 When ordering a terminal guard quote the appliance name and model number 4 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated EXE Fue Deflector Fig 3a If required a flue deflector is available from your Potterton stockist 2 Push the flue deflector over the teminal end and rotate to the optimum angle for deflecting plume Secure the deflector to the terminal with screws provided 93 Elbow Plume Outlet Assembly 60 Support Bracket _ 600 Exh
42. iler in the upright position 27 Pressure Relief Valve Fig 33 Discharge Pipe 28 Q Baxi Heating UK Ltd 2007 Fig 32 Wall Plate 10 0 Installation Fitting The Boiler Remove the sealing caps from the boiler connections 2 Lift the boiler using the lower edges Engage the slots at the top rear of the boiler on the wall plate Fig 32 3 Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections The rubber washers must be used on the gas connection 4 Tighten all the connections Fitting the Pressure Relief Discharge Pipe Fig 33 Remove the discharge pipe from the kit 2 Determine the routing of the discharge pipe in the vicinity of the boiler Make up as much of the pipework as is practical including the discharge pipe supplied 3 The pipework must be at least 5bmm diameter and run continuously downwards to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside discharge point IMPORTANT Make all soldered joints before connecting to the pressure relief valve 10 6 Condensate Drain see section 7 6 Connect the condensate drain using the 1 BSP nut and
43. ion see Section 7 4 After considering the site requirements see Section 7 0 position the fixing template on the wall ensuring it is level both horizontally and vertically 2 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 horizontal fixing slots 3 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 30 4 Note the shaded area on the template Pipework may be routed upwards behind the boiler providing it does not conflict with the shaded area 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 16mm 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 Flushing Connect a tube to the central heating flow or return pipe Fig 31 2 Flush thoroughly see System Details Section 6 2 Preparing The Boiler Remove all packaging 2 Stand the boiler on its base by using the rear lower edge as a pivot NOTE A small amount of water may drain from the bo
44. ipes are subjected to internal pressure fluctuations when WC s are flushed or sinks emptied then back pressure may force water out of the boiler trap and a cause appliance lockout External termination to a purpose made soak away Boiler Examples are shown of the following methods of termination i to an internal soil amp vent pipe 500mm min ii via an internal discharge branch e g sink waste iil to a drain or gully iv to a purpose made soakaway Holes in the soak away must face away from the building 16 Q Baxi Heating UK Ltd 2007 Terminal Position with Minimum Distance Fig Directly below an opening air brick opening windows etc 300 Above an opening air brick opening window etc 300 Horizontally to an opening air brick opening window etc 300 D Below gutters soil pipes or drain pipes 25 E Below eaves 25 F Below balconies or car port roof 25 G From a vertical drain pipe or soil pipe 25 From an internal or external corner 25 Above ground roof or balcony level 300 From a surface or boundary line facing a terminal 600 From a terminal facing a terminal Horizontal flue 1200 From a terminal facing a terminal Vertical flue 600 L From an opening in carport e g door window into the dwelling 1200 Vertically from a terminal on the same wall 1500 Horizontally from a terminal on the same wall 300 From adjacent wall to flue vertical only 300 S From
45. is publication may be reproduced or transmitted in any form or by any means or stored in any retrieval system of any nature including in any database in each case whether electronic mechanical recording or otherwise without the prior written permission of the copyright owner except for permitted fair dealing under Copyrights Designs and Patents Act 1988 Applications for the copyright owner s permission to reproduce or make other use of any part of this publication should be made giving details of the proposed use to the following address The Company Secretary Baxi Heating UK Ltd Pentagon House Sir Frank Whittle Road Derby DE21 4XA Full acknowledgement of author and source must be given WARNING Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages Baxi Heating UK Ltd is a BS EN ISO 9001 Accredited Company Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person s Self Certification Scheme Install and Commission this appliance to manufacturer s instructions Complete the Benchmark Checklist If you notify via CORGI Scheme CORGI will then notify the relevant Local Authority Building Control Scheme on member s behalf Scheme Members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days You must ensure that the notification num
46. lly recommission the appliance and system Lock Nut Condensate Trap Fig 77 Fig 76 Disconnect the two sensing wires from the trap connections Sensing Wires Inlet Pipe 2 Squeeze together the wire spring clip to release and ease the inlet pipe from the trap spigot 3 Undo the nut securing the condensate drain pipe to the trap Disconnect the pipe and sealing washer 4 From underneath the boiler remove the screws D T securing the trap bracket P 3 5 Remove the trap and bracket from the boiler Undo Fig 77 the locknut securing the trap to the bracket Condensate 6 Drain Pipe 42 Q Baxi Heating UK Ltd 2007 Reassemble in reverse order Grub Screw Pressure Relief Valve Control Box Cover Fig 79 Selector Switch Drive Pins Baxi Heating UK Ltd 2007 14 0 Changing Components Pressure Relief Valve Fig 78 Drain the primary circuit 2 Disconnect the discharge pipe from the valve Using a suitable hexagon key undo the grub screw sufficiently to release the valve 3 Note the orientation of the valve rotate it and withdraw it from the manifold 4 Fit the new valve and O ring seal and set to the previously noted orientation Reassemble in reverse order PREM Fig 80 Note the
47. lt finding checks Check that gas water and electrical supplies are available at the boiler Electrical supply 230V 50 Hz CH water system pressurised to 0 5 bar when the boiler is cold The preferred minimum gas pressure is 9 5mbar natural gas or 36mbar propane 2 Carry out electrical system checks i e Ground Continuity Resistance to Ground Short Circuit and Polarity with a suitable meter NOTE These checks must be repeated after any servicing or fault finding 3 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 Refer to Section 15 0 Illustrated Wiring Diagram for position of numbered terminals Central Heating Follow operational sequence NOTE When instructed to turn the selector to the reset position turn the selector switch fully anticlockwise against the spring pressure to Reset position and hold for 2 seconds to reset the boiler Turn selectorto NO Go to section A Q neon illuminated YES Q3 neon flashing Go to section B YES External controls and where Ensure controls are set to fitted integral timer calling for demand and verify the heat contacts are closed NO i Primary flow switch operated neon flashing Go to section C YES Turn ff thermostat to max Pump runs Turn selector to reset position If regular
48. lushed out Using for example Betz Dearborn Sentinel X300 or X400 or Fernox Superfloc Universal Cleanser They should be used following the flushing agent manufacturer s instructions System additives corrosion inhibitors and flushing agents descalers should comply to BS7593 requirements e g Betz Dearborn Sentinel X100 and Fernox Copal which should be used following the inhibitor manufacturer s instructions Failure to flush and add inhibitor to the system will invalidate the appliance warranty t is important to check the inhibitor concentration after installation system modification and at every service in accordance with the manufacturer s instructions Test kits are available from inhibitor stockists For information or advice regarding any of the above contact Technical Enquiries Bypass The boiler is fitted with an automatic integral bypass System Control The boiler is designed for use in a heating system that incorporates external controls i e a minimum of a timer device 2 Suitable timer kits are available as optional extras 3 For optimum operating conditions and maximum economy the fitting of a programmable room thermostat is recommended Fig 4 Fig 5 Pressure Relief Valve Double Stop Check Stop Valve Valve Valve Temporary CH Hose Mains Return Inlet Fig 6 Discharge Pipe 12 Baxi Heating UK Ltd
49. m pressure Reset and the larger nut 8mm maximum pressure T 3 Using a suitable spanner adjust the relevant nut until Power On the correct pressure is achieved Neon Central Heating Hot Water Temperature Contre Control 4 Once the pressure has been set tum the boiler off Fig 51 and disconnect the pressure gauge 5 Tighten the pressure test screw and refit the modulator to the valve Reassemble in reverse order Baxi Heating UK Ltd 2007 33 Facia Panel 34 Baxi Heating UK Ltd 2007 Front Panel Fig 52 12 0 Completion Completion Hinge the facia panel upwards and refit the case front panel Tighten the securing screws Fig 52 2 Instruct the user in the operation of the boiler and system explaining the operational sequence 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 1 5 813 An example of this is given in 1 5 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist
50. model serial number and Gas Council number and is situated on the control box It is visible when the case front panel is removed Fig 1 6 The boiler is intended to be installed in residential commercial light industrial E M C environments on a governed meter supply only 7 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit part no 5111073 8 All systems must be thoroughly flushed and treated with inhibitor see section 6 2 Optional Extras Various flue extensions bends vertical flue kits control accessories etc are available as optional extras These are detailed in a separate publication 24 25 26 27 28 29 30 40 50 60 70 80 9 9 9 o o o o o o a 65 2 0 General Layout Layout Air Pressure Switch 2 Expansion Vessel 3 Burner Manifold 4 Automatic Air Vent 5 DHW Plate Heat Exchanger 6 Circulation Pump 4 Drain Off Point 8 Pressure Relief Valve 9 Optional Integral Timer 0 Central Heating System Pressure Gauge 2 3 3 Way Valve Assembly 4 Condensate Trap 5 Flame Sensing Electrode 6 Spark Electrode 7 Burner 8 Primary Heat Exchanger 9 Fan Assembly 20 Secondary Heat Exchanger 21 On Off Reset Selector Switch 22 Central Heating Temperature Control 23 Hot Water Temperature Control 24 Flame
51. ms e This bend is equivalent to metre Baxi Heating UK Ltd 2007 8 0 Flue Options Twin amp Vertical Flue Systems Maximum permissible equivalent flue lengths are Vertical Concentric 3m Vertical Twin Pipe 2m Both the air and flue duct can be up to 12 metres long each 4 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 45 bend 0 5 metres 93 bend 1 0 metres Twin Flue Pipe 45 bend 0 25 metres 91 5 bend 0 50 metres The elbow supplied with the standard horizontal flue is not included in any equivalent length calculations NOTE Flue length is measured from point X to Y as shown The total equivalent length for this example is 6 5 metres Equivalent of Sub total Length Value fittings pipes 1m extension 45 bend 91 5 bend Equivalent Length Value 1m extension 45 bend 91 5 bend Equivalent Length Flue Duct 6 5m 8 0 Flue Options Flue Accessories Key Accessory Size Baxi Code No Concentric Flue System 100mm diameter Al orizontal flue Terminal 5111073 A orizontal flue Terminal incl elbow 5118489 B Flue extension 1000mm 5111074 C Flue Bend 93 5111075 D Flue Bend pair 135 5111085 U Pipe support 100mm 5111080 R Vertical flue adaptor 5111070 P Wall Liner 5111067 5 Flue Terminal Deflector 5111068 Twin Flue Sy
52. nt edition of Institute of Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing Clearances Figs 8 amp 9 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 access during routine maintenance and air movement Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler NOTE The boiler can be operated with a clearance of 5mm at the right This is also sufficient for routine maintenance However a clearance of 20mm is required if it is necessary to remove the secondary heat exchanger This should be considered when siting the appliance and in the event of any subsequent alteration in the area of installation 7 0 Site Requirements Ventilation of Compartments Where the appliance is installed in a cupboard or compartment no air vents are required 2 BS 5440 Part 2 Clause 4 2 refers to room sealed appliances installed in compartments The appliance will run sufficiently cool without ventilation Gas Supply The gas installation should be in accordance with the relevant standards In GB this is BS 6891 In IE this is the current edition of I S 813 Domestic Gas Installations 2 The connection to the appliance is a 22mm copper Ux tail located at the rear of the gas se
53. ntral 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 Potterton supports AA enchmark WRAS henchman J pro 06 The code of practice for the installation commissioning amp servicing of central heating systems Baxi Heating UK Ltd 2007 Section Page Legislation 4 1 0 Introduction 6 2 0 General Layout 7 3 0 Appliance Operation 8 4 0 Technical Data J 5 0 Dimensions and Fixings 0 6 0 System Details 7 0 Site Requirements 4 80 Flue Options 8 9 0 Plume Displacement 23 10 0 Installation 27 11 0 Commissioning the Boiler 32 12 0 Completion 34 13 0 Servicing the Boiler 35 14 0 Changing Components 37 15 0 Illustrated Wiring Diagram 47 16 0 Fault Finding 48 17 0 Short Parts List 53 Benchmark Checklist 54 Baxi Heating UK Ltd 2005 All rights reserved No part of th
54. pipe and outlet manifold to the new valve ensuring that the O ring seals are in place Fig 68 10 Reassemble in reverse order and check the burner pressure Section 1 2 Central Heating Temperature Sensor Fig 69 Flow Pipe 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 Central Heating Temperature Sensor Safety Thermostat Fig 69 Pull the electrical connections off the thermostat 47 9 9 f JS 3 2 Remove the screws securing the thermostat to the mounting plate on the flow pipe 3 Reassemble in reverse order The thermostat is not polarised either wire can fit either terminal on the thermostat DHW Temperature Sensor Fig 70 Safety Thermostat Turn off the mains water supply and draw off the residual domestic hot water Fig 69 2 2 Ease the retaining tab on the sensor away and disconnect the electrical plug Plate Heat 3 Unscrew the sensor from the plate heat exchanger Exchanger manifold Examine the sealing washer replacing if necessary 4 Reassemble in reverse order The plug will only fit one way DHW Temperature 40 Baxi Heating UK Ltd 2007 Sensor 14 0 Changing Components RAVE Pump Head Only Fig 71 Drain the primary
55. r Commissioning the Boiler Reference should be made to BS 5449 Section 5 when commissioning the boiler Screw 2 Open the mains water supply to the boiler Automatic Air Veni 3 Open all hot water taps to purge the DHWV system 4 Ensure that the filling loop is connected and open then open the heating flow and return valves on the boiler 5 Open the screw on the automatic air vent Fig 45 6 The system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 7 Pressurise the system to 1 0 bar then close and i 7 Pum 4 Fig 45 j disconnect the filling loop 8 Turn the gas supply on and purge according to in GB BS 6891 and in IE 1 5 813 Domestic Gas Installations 9 Test for gas soundness 10 If at any time during commissioning it is required to terminate a particular cycle e g the pump overrun period turn the selector to the OFF position and then back to either Fig 47 Selector Switch Fig 46 O Power On E TREO Central Heating Hot Water Temperature Control Temperature Control Fig 47 32 Q Baxi Heating UK Ltd 2007 11 0 Commissioning the Boiler Checking the Burner Pressure Pressure Test Point Sealing Screw Turn on the gas and electrical supplies to the boiler and ensure that all external controls are calling for heat
56. r systems BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems 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 TWO PEOPLE Do not handle or lift unless you feel physically able Wear appropriate Personal Protection Equipment e g protective gloves safety footwear etc Preparation Co ordinate movements know where and when you are both going Minimise the number of times needed to move the boiler plan ahead Always ensure when handling or lifting the route is clear and unobstructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep your back straight bend your knees Don t twist move your feet avoid bending forwards and sideways and keep the load as close to your body as possible Where possible transport the boiler using a sack
57. resetting is required or appliance still Go to sections J amp M does not operate investigation is necessary NO Fan runs at max speed neon flashing NO m WE neons flashing Go to section D Air pressure NO B neon flashing switch proved Go to section E YES YES Turn selector to the reset Spark at ignition electrodes A aeon YES position If the neon does not for up to 10 seconds A 8 extinguish go to sections amp NO YES Replace PCB urner an 5 ices Go to section F illuminated YES K Burner extinguishes YES neon flashing after 10 seconds Go to sections I amp L NO NO Burner output modulates until set Go to section temperature is reached YES YES YES YES 48 Baxi Heating UK Ltd 2007 16 0 Fault Finding Domestic Hot Water Follow operational sequence selectorto E A Replace diaph YES YES Is mains water YES TUS filter and differential ERI agm assembly clean YES NO Turn thermostat to max Open DHW tap fully DHW DHW flow rate more than DHW flow valve rod i 2 5l min obstructed flow switch operated T Replace DHW flow Primary water is diverted Continuity across DHW flow mieroswitch from CH system to DHW microswitch terminals and heat exchanger and flow PCB A5 connector microswitch operated terminals 5 amp 6 Replace PCB g neon illuminated YES YES Primary flow switch operated
58. rminal block connect the input cable and tighten the screws 6 If an external control is to be connected it can be done at this point Run the input cable from the external control through the second cable clamp on the boiler chassis Refer to the instructions supplied with the control 7 To connect external control s remove the link between terminals amp 2 The 230V supply at terminal must be connected to the external control The switched output from the external control must be connected to terminal 2 Fig 43 NOTE If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Fig 43 IMPORTANT The external control MUST be suitable for 230V switching 8 Ensure that both mains input and where fitted external control input cables have sufficient slack to allow the control box to drop down Tighten the cable clamp s on the boiler chassis 9 If the optional integral timer is to be used it should be fitted at this point Refer to the instructions supplied with the timer NOTE An external frost thermostat cannot be used with the integral timer Preliminary Electrical Checks 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 Ground Continuity Resistance to Ground Short Circuit and Polarity 3 11 0 Commissioning the Boile
59. rvice 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 Electrical Supply External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current I E e Wiring Regulations In IE reference should be made to the current edition of ETCI rules 2 The mains supply is 230V 50H fused at 3A NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Connection may be via a fused double pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only Gas Service Cock Baxi Heating UK Ltd 2007 15 7 0 Site Requirements Termination to an internal soil and vent pipe Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER Boiler The condensate discharge pipe MUST NOT RISE at any point along its length There MUST be a fall of AT LEAST 2 5 50mm per metre along the entire run The condensate outlet terminates in a BSP nut and seal AAA 450mm min for the connection of 21 5mm in plastic overflow pipe which should generally discharge internally into the household drainage sys
60. sary to remove the heat exchanger as described in Section 14 3 and slide out the side pieces 998 4 The combustion box door insulation piece be Rear Insulation replaced by carefully bending up the two retaining tabs 5 Replace all insulation pieces and reassemble in reverse order Side Insulation Combustion Box Door Front Insulation Fig 67 Baxi Heating UK Ltd 2007 39 14 0 Changing Components Gas Valve Fig 68 Undo the nut on the gas feed pipe under the boiler Modulator 7 Wires 27 a 2 Completely undo the securing screws and hinge the 24 facia panel down Ignition e C Gas Valve 3 Disconnect the wires from the valve modulator and the ignition lead from the spark generator Disconnect the pressure sensing pipe from the valve Undo the screw securing the spark generator electrical plug to the valve and disconnect the plug 4 Pull the earth wire off the spade terminal on the valve 5 Remove the screws securing the inlet pipe flange to the boiler bottom panel and those securing the outlet manifold to the burner manifold Electrical Plug 6 Remove the valve from the boiler 7 Note the orientation of the inlet pipe and outlet manifold Undo the securing screws and remove the pipe and manifold Earth Wire Inlet Pipe v 8 Examine the O ring seals for damage replacing as Gas Feed Pipe necessary 9 Fit the inlet
61. stem 80mm diameter E Flue extension pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend pair 135 5111086 J Vertical flue boiler adaptor kit 5111079 H Vertical flue adaptor 5111084 W Pipe support pair 80mm 5111081 Vertical Flue Kits K Vertical flue terminal 5111078 L Lead tile 25 45 246141 Lead tile 35 55 246142 M Roof cover plate 246143 N Flat roof flashing 246144 20 Q Baxi Heating UK Ltd 2007 Outer Sleeve Air Duct Blank Blanking Plate Inner Sleeve Gasket oe Restrictor Baxi Heating UK Ltd 2007 8 0 Flue Options For Twin Flue Systems fit the adaptors as follows Flue Duct Adaptor Insert the inner sleeve into the flue duct outlet of the boiler flue adaptor Engage the outer sleeve in the boiler flue adaptor Ensure that it is pushed fully in Take the air duct blank and fit into the outer sleeve and over the inner sleeve Air duct adaptor Undo the screws securing the blanking plate to the boiler top panel Discard the plate 2 There are three restrictor plates supplied in the kit One marked 23 and one marked 27 these can be discarded The third restrictor MUST be positioned as shown in the diagrams below 3 Take one of the gaskets supplied in the kit and place on the boiler top panel 4 Align the appropriate restrictor as shown Position the second gasket over the restrictor 5 Using the screws pr
62. t 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 27 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure using two of the screws supplied 21 The remaining screw must be used to secure the Fig 27 adaptor to the concentric terminal 22 When the plume outlet is positioned under a balcony or other projection Fig 28 it must protrude at least 200mm Min 200mm it is not necessary to extend it further than this 23 When under balconies or projections it is permissible to rotate the concentric flue length up to 70 clockwise or anti clockwise Fig 29 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 subjetc to rain entry Fig 28 70 Concentric Flue Length E shown end on Outlet Spigot Fig 29 26 Baxi Heating UK Ltd 2007 8 For Side Flue Exit Fig 30 Wall Plate Flushing Tube Central Heating Return Fig 3 Baxi Heating UK Ltd 2007 10 0 Installation EM Initial Preparation The gas supply gas type and pressure must be checked for suitability before connect
63. t modulating coil of gas valve is YES Max burner press approx 9V DC 13 DC LPG Min burner press approx IV DC Current at modulating coil of gas valve is Use an instrument with average function for this NO 30 230 mA DC 45 310 mA DC LPG H Check and correct if necessary Ignition electrode and lead 2 Electrode connection 230V at Main PCB Replace PCB connector across terminals 3 amp 4 Check wiring Replace gas valve 3 Spark gap and position electrical plug amp igniter assembly Baxi Heating UK Ltd 2007 5I 16 0 Fault Finding Ensure that mains input terminal L is Live 230V and N is Neutral 0 Check and correct if necessary Flame sensing electrode and lead connections 2 Electrode position Replace PCB Flame current should be yA approx Replace flame sensing electrode Overheat thermostat operated or Allow to cool Continuity i me Replace safety faulty i e continuity across across thermostat terminals i thermostat thermostat terminals more than 1 5 ohm Replace PCB K Check terminal of ON OFF RESET selectorisin AS p Replace ON OFF RESET selector connection with PCB A4 connector terminal 2 Check electrical continuity across terminals amp a of ON OFF RESET selector when turned to Reset position E NN Replace PCB If checks in section are completed successfully blockage of the condensate drain or trap may have occurred If checks in section J
64. tem If this is not possible discharge into outside drain is acceptable 2 Ensure the discharge of condensate complies with any External termination via internal national or local regulations in force Boiler discharge branch BS 6798 2000 amp Part of the Building Regulations give e g sink waste downstream further guidance 3 The discharge pipe should be run in a proprietary drain pipe Pipe must terminate material e g PVC PVC U ABS PVC C or PP Sink above water level but below surrounding 4 Metal pipework is NOT suitable for use in condensate surface discharge systems 5 The pipe should be a minimum of 21 5mm diameter and must be supported using suitably spaced clips to prevent sagging 6 It is advisable to keep the condensate pipe internal 7 External runs greater than 3 metres or runs in cold areas External termination to a drain or gully should se 2mm waste pipa Boiler Eier natat 8 If the boiler is fitted in an unheated location the entire water level but below condensate discharge pipe should be treated as an external surrounding surface run 9 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used 10 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered If soil pipes or waste p
65. terminal guard must be provided IMPORTANT Only ONE 25mm clearance is allowed per installation Under car ports we recommend the use of the plume displacement kit The terminal position must ensure the safe and nuisance free dispersal of combustion products IMPORTANT If fitting a Plume Displacement Flue Kit the air inlet must be a minimum of 00mm from any opening windows or doors see Section 9 0 Opening Window Likely flue positions requiri a flue terminal guard Baxi Heating UK Ltd 2007 Fig 11 or Door Fig 12a Horizontal Plume Displacement Kit 60 100 IM Extensions 45 amp 93 bends are also available see Section 9 0 NOTE Horizontal flue pipes should always be installed with a 1 5 fall from the terminal to allow condensate to run back to the boiler This bend is equivalent to This bend is equivalent to metre Total equivalent length upto 3m A B C 2x90 Bends 18 Baxi Heating UK Ltd 2007 8 0 Flue Options EN Horizontal Flue Systems The Potterton Performa 30 HE can be fitted with either horizontal vertical or twin flue systems as illustrated 2 The standard fl
66. 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 600 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 1 5 metres Additional bends may be fitted in the concentric flue but the equivalent length must be reduced by metre 93 bend or 0 5 metres 45 bend 7 60 metre extensions including support additional 93 amp 45 elbows are available Any amp 45 elbows must be accounted for when ca lengths NOTE Permitted positions of the plume ou bracket and additional 93 culating flue let relative to doors windows etc are the same as for conventional concentric flues as detailed in the main Instal ation amp Servicing Instructions and BS5440 Pt It is NOT necessary to fit a terminal guard over the air plume outlet inlet or the 23 9 0 Plume Displacement Determining Permissible Lengths In the graph the solid line diagonal represents the relationship between the concentric flue assembly and any extensions and the 60 exhaust and any extensions or additional bends 60 Exhaust metres 60 Exhaust metres
67. the positions of the two sensing tubes and three wires and remove them 3 Remove the two screws holding the pressure switch to the bracket on the combustion box top panel 4 Fit the new pressure switch and reassemble all components in reverse order of dismantling 37 Pipe Connecting eS Clips Heat Exchanger Return Pipe Fig 64 Electrodes yi Burner 8 ATi zt Electrode T Grommets 7 Fig 65 Electrode Leads 38 Q Baxi Heating UK Ltd 2007 14 0 Changing Components Heat Exchanger Fig 64 Remove the fan as described in section 14 1 2 Drain the primary circuit Prise the three pipe connecting clips off the joints in the flow and return pipes Remove the heat exchanger return pipe 3 Lift the heat exchanger to disconnect the flow pipe joint Withdraw it from the appliance taking care not to damage the rear insulation piece 4 Fit the new heat exchanger 5 Reassemble in reverse order of dismantling and repressurise the system Burner Fig 65 Remove the four screws securing the combustion box door and remove the door 2 Undo the screws securing the burner to the injector manifold Draw the burner out of the combustion box pulling the electrode grommets from the slots in the combustion box lower panel 3 Disconnect the electrode leads and grommets from he electrodes Completely remove the burner 4 Undo the s
68. ue is suitable only for horizontal applications 3 Maximum permissible equivalent flue lengths are Horizontal Concentric 3m Vertical Concentric 3m Vertical Twin Pipe 12m 4 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths Concentric Pipes 45 bend 0 5 metres 93 bend 0 metres Twin Flue Pipe 45 bend 0 25 metres 91 5 bend 0 50 metres The elbow supplied with the standard horizontal flue is not included in any equivalent length calculations 6 The illustrations opposite show examples of maximum equivalent lengths 7 Full details of part numbers and descriptions of all optional flue components and kits can be found in the Baxi Flue Guide 8 Instructions for guidance and fitting are included in each kit where appropriate NOTE Flue length is measured from point X to Y as shown Vertical Flues Twin Pipe Vertical Flues Total Equivalent Length A B C 1x90 Bend Roof l erminal All vertical and angled runs must be included measured from the boiler adaptor point X to the joint with the flue terminal point Y One 91 5 bend or two 45 bends can be included without reduction of the flue length If further elbows are required the flue length must be reduced by the following amounts Y metre for each 91 5 elbow 0 5 metre for each 45 elbow
69. ulations Scotland Building Regulations Northern Ireland he Water Fittings Regulations or Water Byelaws in cotland he Current E E Wiring Regulations aea dvs Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent Person and installed in accordance with the current edition of 1 5 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation All systems must be thoroughly flushed and treated with inhibitor see section 6 2 Codes of Practice most recent version should be used In GB the following Codes of Practice apply Standard Scope BS 6891 Gas Installation BS 5546 Installation of hot water supplies for domestic purposes BS 5449 Forced circulation hot water systems BS 6798 Installation of gas fired hot water boilers BS 5440 Part Flues BS 5440 Part 2 Ventilation BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems In IE the following Codes of Practice apply Standard Scope LS 813 Domestic Gas Installations The following BS standards give valuable additional information BS 5546 Installation of hot water supplies for domestic purposes BS 5449 Forced circulation hot wate
70. uring Screw Baxi Heating UK Ltd 2007 Fan Hood 14 0 Changing Components IMPORTANT When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started When the new component has been fitted turn the selector switch fully anticlockwise against the spring pressure to the Reset position and hold for 2 seconds to reset the boiler before recommissioning See Section 13 1 Annual Servicing for removal of case panel door etc Fan Figs 62 amp 63 Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them 2 Slacken the screws on the fan spigot outlet pipe clamps Ease the clamps inwards over the pipe 3 Draw the outlet pipe away from the boiler 4 Remove the four screws securing the combustion box door and remove the door 5 Ease the front edge of the left hand baffle upwards disengaging the spring clip Disengage the tab on the baffle from the slot in the fan hood 6 Undo the screws securing the fan hood to the appliance back panel and draw the fan and hood assembly forwards 7 Remove the screws and spring washers securing the fan to the hood 8 Fit the new fan to the hood using the screws and spring washers previously removed 9 Reassemble in reverse order of dismantling Pressure Switch Fig 61 Remove the fan as described in section 14 1 2 Note
71. utomatic air vent v 3 Reassemble in reverse order Pump Wiring Cover Fig 73 Baxi Heating UK Ltd 2007 4l 14 0 Changing Components Pressure Gauge Figs 74 amp 75 Drain the primary circuit and undo the nut on the pressure gauge capillary 2 Remove the timer cover and ease the timer wiring Fig 74 aside Undo the screws securing the gauge retaining bracket Pressure Gauge Capillary 3 Remove the bracket and gauge assembly Depress Gauge Retaining the barbs on the side of the gauge and remove the Bracket retaining bracket 4 Reassemble in reverse order Bs x nd i BALE Expansion Vessel Fig 76 To replace the expansion vessel it is necessary to remove the boiler from the wall Fig 75 Note Alternatively a vessel of equivalent capacity can be fitted on the system return pipe as close as possible to the boiler 2 Drain the system and undo all gas water and condensate drain connections Remove the flue elbow 3 Lift the boiler off the wall plate and lay it on it s side on a clean flat surface Ks 4 Undo the nut on the vessel outlet spigot and Retaining Clip remove the locknut and spring washer securing the spigot to the boiler chassis 5 Undo the screws and remove the appliance upper cross member Slide the expansion vessel out of the retaining clips Boiler Chassis 6 Reassemble in reverse order Fu
72. y of the extensions the excess material must be cut from the plain end of the pipe Determine the position of the 600 exhaust and mark Fig 21 on the wall a suitable position for the support bracket If extensions are being used a support bracket is supplied in each kit 12 Drill the wall and fit the bracket s using the plug and screw provided 13 Mark and drill the 600 exhaust using a 2mm bit as shown in Fig 23 Complete the installation of the 600 exhaust securing in the brackets A 14 Fit the 93 elbow plume outlet and secure with the two remaining screws supplied Ensure the plume outlet is Fig 24 Baxi Heating UK Ltd 2007 at least 45 to the wall and that the peak is uppermost Fig 24 25 9 0 Plume Displacement General Fitting Notes cont Plume Outlet Elbow 5 For aesthetic purposes it is permissible to route the 60 exhaust in an enclosed box but the air inlet and plume outlet MUST remain in free air 6 It is also possible to separate the plume outlet from the 93 elbow to allow the flue to be installed as shown in Fig 25 7 To do this first slacken the two screws retaining the plume outlet to the elbow and remove the outlet Fig 26 The elbow can now be used to connect the vertical to horizontal 60 exhaust Fig 25 Retighten the screws in the elbow 18 The outlet can now be fitted into the female end of an 600 extension piece It mus

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