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Baxi Potterton Gold FSB 30 HE Boiler User Manual

1. NO Remove Gas Valve amp check inlet filter for blockage O therwise incorrect gas supply to boiler YES Is Condensate Trap blocked or water on terminals YES Clear blockage and dry sensors NO Is Condensate Pump reservoir full YES Check and if necessary change over level switch see Section 13 5 NO YES Replace spark or flame detection probe and spark or flame detection probe damaged gaskets NO spark gap between 3 and 4mm NO Set spark gap to 3 5mm YES YES ls the burner blocked or damaged wiring from PCB to spark probe amp flame detection probe O K NO YES Rectify wiring Clean peel ae as Baxi Heating UK Ltd 2011 17 0 Fault Finding Gas Valve 5 way Connector Plug YES 5 way connector from gas valve Is there 240 Vdc between amp J during ignition Replace Gas Valve NO the larger of the two 6 way PCB connectors Is there continuity from to L amp from J to K NO Lead from PCB to Gas Valve faulty YES Replace PCB 6 way Connector Replace PCB 53 17 0 Fault Finding Lights On Off x OQ amp OOO OVERHEAT LOCKOUT Disconnect black stat on flow pipe W hen flow lt 60 C is there continuity across stat NO Replace Stat Reconnect stat Disconnect fan stat
2. 10 0 Installation Making The Electrical Connections WARNING This boiler must be earthed IMPORTANT Four core cable is required to supply the boiler as a permanent live is necessary for the operation of the condensate pump and frost protection 1 The electrical connections are on the right hand side of the boiler Depending upon the nature of the installation it may be preferable to wire up to the boiler first before manoeuvering into position 2 Undo the two screws securing the cable clamp and place to one side Fig 31 3 Route the incoming electrical cable s from the system control wiring centre through the grommet in rear of the boiler and the grommet in the support bracket This will prevent damage to the cable s 4 Lay the cable through the cable clamp to gauge the length of wire required when it is connected to the 4 way terminal block 5 Connect the S L N and P L wires to the 4 way terminal block Fig 33 and refit the cable clamp Fig 31 INTEGRAL PROGRAMMER If the optional integral programmer is being fitted it can be done at this stage Consult the instructions supplied in the programmer kit Check the electrical installation for earth continuity short circuits resistance to earth correct polarity and fuse rating 33 11 0 Electrical Schematic W iring Diagram Condensate Removal System Condensate Condensate Level Switch Condensate Pump Fan I I
3. eseseeceseeeeeseeetes Tail Ralim we A a e ee en Hole for Tail Electrical Cable a ss a A Hole for Transit ee eenei aes Pracer Drain O utlet Gas Connection Baxi Heating UK Ltd 2011 10 0 Installation Check Site Requirements before commencing Initial Preparation amp Installation 1 Remove the outer carton 2 For the boiler to operate correctly it must be level in both planes Place the fixing template in the proposed boiler position ensuring that it is level 3 Mark the centre of the flue hole rear exit For side exit project the horizontal side flue centre line into the corner of the room and along the wall to where the flue hole will be drilled Fig 20 The diagram Fig 21 shows the dimensions required to ensure any horizontal flue is installed with the correct fall to the boiler Mark the offset V dimension and if required mark the position of the gas water and condensate pipes Remove the template 4 Cut the hole for the flue minimum diameter 125mm see table Fig 20 for wall thicknesses and flue hole diameters 5 Complete any pipework and wiring that will be inaccessible once the boiler is in position 6 Undo the securing screws and remove the facia front door panel and top panel see Figs 1 amp 2 on page 6 Remove the securing screw and disengage the pipe access panel Making the W ater Connections 1 If desired the flow and return tails supplied with th
4. 59 All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request POTTERTON A Trading Division of Baxi Heating UK Ltd 3879156 Brooks House Coventry Road W arwick CV34 4LL After Sales Service 0844 871 1560 Technical Enquiries 0844 871 1555 W ebsite www potterton co uk e amp oe PART OF BDR THERMEA Baxi Heating UK Ltd 2011 Comp No 720896601 6 11
5. 3 The connection to the boiler is a 15mm tail on the gas Fig 15 service cock The tail protrudes through the boiler rear panel and is protected by a transit bracket which may be removed to aid connection 4 Ensure that the pipework from the meter to the boiler is of adequate size If the boiler is further than 3 metres from the Gas Meter 22mm pipe should be used Do not use pipes of a smaller diameter than the boiler gas connection Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current I E E W iring Regulations In IE reference should be made to the current edition of ETC rules 2 The mains supply is 230V 50Hz fused at 3A 500mm Min NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance and system For Servicing Purposes Connection may be via a fused double pole isolator with a contact separation of at least 3mm in all poles which must be in an accessible position to the user and serve the boiler and system controls only There is no method of isolating the boiler at the user interface 3 Four core cable is required to supply the boiler as a permanent live is necessary for the operation of the condensate pump and frost protection 520mm gt 5mm Min F _ gt lt lt Fig 16 In O peration 16 Baxi Heating UK Ltd 2011
6. W hen fan temp lt 60 C is there continuity across stat NO Replace Stat YES Reconnect stat Disconnect the larger of W iring from PCB to lt the 6 way PCB connectors thermostats faulty Is there continuity across M 6 way Connector Disconnect thermistor red sensor on flow pipe Is resistance between 0 5kQ amp 20kQ Replace thermistor combustion chamber Replace combustion door seal damaged or not in chamber pe seal amp trim seal place Replace PCB 54 Baxi Heating UK Ltd 2011 FAN LOCKOUT Lights n NO 3 way PCB connector amp unplug fan Is there continuity from N to O amp from P to Q Rectify wiring the smaller of the 6 way PCB connector Is there continuity from R to S amp from T to U amp from VtoW Rectify wiring YES Replace fan Baxi Heating UK Ltd 2011 uv lt A D 17 0 Fault Finding NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after the boiler has been electrically isolated Fan PCB Connection Connection lt lt lt 0 lt Q gt Fan PCB Connection Connection _ gt gt lt lt 5 _ U W Viewed from W ire Entry end 55 17 0 Fault Finding THERMISTOR Unplug thermistor Is thermistor resistance between Replace thermistor 05kQ
7. Condensate Pump Flow Graph Head metres Is 2 25 3 35 4 Flow l min Gravity Drain min fall 3 N ote The point of discharge from the pumped length of condensate pipe point A must not be below Max Head 3 metres the level of the pump whether discharging direct into a drain or into an additional gravity drain i ones Alternative H orizontal Discharge Fig A ane 10mm PVC Pipe es 8 5mm ID e5 eeneenne sent Securing Clip rT ee 85mm fe D Condensate Pipe 215mm OD toi Direct Connect O verflow Pipe Fitting Fig B Baxi Heating UK Ltd 2011 7 0 Site Requirements Condensate Drain General Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler 1 Ensure the discharge of condensate complies with any national or local regulations in force BS 6798 amp Part H 1 of the Building Regulations give further guidance 2 If any further drain pipe is required additional to that supplied with the boiler it should be run in a proprietary material e g PVC PVC U ABS PVC C or PP 3 Metal pipework is NOT suitable for use in condensate discharge systems 4 Any pipe fitted externally must be kept as short as possible to minimise the potential of freezing and must be insulated using waterproof material 5 W hen discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be conside
8. K cont 4 va 16 For aesthetic purposes it is permissible to route the 70 exhaust in an enclosed box but the air inlet and plume outlet MUST remain in free air 17 It is also possible to separate the plume outlet from the 93 elbow to allow the flue to be installed as shown in Fig H 18 W hen the plume outlet is positioned under a balcony or other projection Figs amp J it must protrude at least Fig H 200mm it is not necessary to extend it further than this 200mm Min m Fig 200mm Min Xo A S A Fig J 28 Baxi Heating UK Ltd 2011 Edge of Boiler ete 125mm te m a il re EXAMPLE If the boiler is 2 metres p away from corner of wall the flue f f wall the fl duct hole will be 55mm higher than Example the horizontal side flue centre line F V 55MM This will maintain an approx 1 5 a t backfall to the boiler It is especially 4 Horizontal important to consider this when 7 i i A Side Flue fitting the boiler under a work top j Centre Line Centre 4 Hole d W all Thickness Flue Hole up to 227mm 125mm core drill up to 750mm 150mm core drill h up to 1200mm 175mm core drill Template Fig 20 Backfall to the boiler ie 2m flue offset V position 55mm Flue Duct Hole Offset V mm 13 5 75 3 825 110 mm metres Fig 21 FIOW
9. K Vertical Flue Terminal L Pitched Roof Flashing 25 50 M Roof Cover Plate N Flat Roof Flashing CodeNo 243013BAX 236921 241695 241694 241692 241687 241689 243014BA X 5106888 248167 246137 246136 246135 5121560 5121561 242757 5111081 242802 243015 243131 243016BA X Vertical Flue Adaptor N Gasket Blank Plate Air Duct Adaptor Gasket Baxi Heating UK Ltd 2011 For Vertical Flues For Twin Flues Flue Duct Adaptor 8 0 Flue Options EZI for Vertical Flue Systems 1 Undo the screws securing the blanking plate to the boiler top panel Discard the plate 2 Fix the vertical adaptor and gasket to the top panel with the previously removed screws For Twin Flue Systems 1 Undo the screws securing the blanking plate to the boiler top panel Discard the plate 2 Fix both the air and flue adaptors with their gaskets onto the boiler top panel Secure with screws 23 8 0 Flue Options E For Roof Terminals 1 In the case of a pitched roof 25 50 degrees position Approx the lead tile to replace flash over existing roof tiling Make 1425mm 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 thr
10. 37 2 Locate the facia panel and secure with the screws previously removed Fig 38 3 The Important Ventilation Information label can be removed unless the boiler is installed in an unventilated compartment 13 2 Benchmark Checklist 1 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the boiler and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 2 For IE it is necessary to complete a Declaration of Conformity to indicate compliance to 1S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist Handover 1 Instruct the user in the operation of the boiler and system controls Hand over the User s O perating Installation and Servicing Instructions giving advice on the necessity of regular servicing 2 Demonstrate to the user the action required if a gas leak occurs or is suspected Show them how to turn off the gas supply at the meter control and advise them not to operate electric light or power switches and to ventilate the property 3 Show the user the location of the system control isolation switch and demonstrate its operation 4 Advise the user that they may observe a plume
11. 50Hz The boiler must be connected to an earthed supply A permanent and switched live are required The boiler has a 4 wire connection Power Consumption 80W External Fuse Rating 3A Internal Fuse Rating BS 4265 Fuse 3 15 AT PCB Electrical Protection IPX X W ater Content litres 2 6 Static H ead max 30 metres min 1 metre Low Head 0 2m min System D etail Fully pumped open vented amp sealed systems N o bypass required Controls boiler thermostat safety thermostat flow switch electronic flame sensing temperature protection thermostat amp condensate blockage and level sensors Boiler Flow Temperature adjustable 55 C to 78 C 5 C Condensate Pump Head 3 metres Flow Rate 18 l min Connection 10mm o d pipe supplied Boiler Hydraulic Resistance Chart a 3 Ka nS a Q i A v i 5 N N D iz a Pressure Drop in wg Water Flow Rate litres min 5 0 Dimensions and Fixings DIMENSIONS Atleast 850mm 1 5 520mm 390mm 125mm Min 175mm 150mm The 1 5 fall provided by the elbow is to allow condensate to run back to the boiler for discharge through the Flue 110mm condensate disposal system Fig 7 SIDE FLUE left and right For every 1m of horizontal flue length the clearance above the top of th
12. BS 6891 and in IE I S 813 Domestic Gas Installations 7 Turn the gas service cock anticlockwise to the ON position and check for gas tightness up to the gas valve Fig 34 Turn the power to the boiler ON IMPO RTANT The combustion for this appliance has been checked adjusted and preset at the factory for operation on the gas type specified on the appliance data plate No measurement of the combustion is necessary Do not adjust the air gas ratio valve 8 Having checked That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals Proceed to put the boiler into operation as follows Priming the Condensate Pump 1 Using a funnel and tube carefully pour approximately Litre of tap water into the flue products exhaust at the terminal or flue elbow sampling point to fill the trap and allow the condensate pump reservoir to fill 2 Continue filling with water until the condensate pump operates 3 Check that the condensate drain pipework is not leaking and that it is discharging correctly to drain 4 See Fig 36a for operation of LEDs on boiler facia 12 0 Commissioning the Boiler Check the O perational W orking Gas Inlet Pressure 1 Ensure that all controls are calling for heat and maximum load is applied to the system 2 W ith the boiler operating
13. Benchmark Logbook which was then left on site with the customer W ith the introduction of Self Certification Schemes the Benchmark Logbook is being withdrawn However a similar document in the form of a commissioning checklist and service interval record is incorporated at the back of these instructions This company is a member of the Benchmark initiative and fully supports the aims of the programme Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency Building Regulations require that installations should comply with manufacturer s instructions It is therefore important that the commissioning checklist is completed by the installer The relevant section of Building Regulations only relates to dwellings Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations BSI amp COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS ISO 9001 FM 00866 Installer N otification Guidelines Choose Building Regulations Notification Route Competent Person s Self Certification Scheme Install and Commission this a
14. Fernox F3 and an inhibitor such as Sentinel X100 or Fernox MB 1 3 Full instructions are supplied with the products for further information contact Sentinel 0800 389 4670 or Fernox 0870 870 0362 Failure to flush and add inhibitor to the system will invalidate the appliance warranty 4 It is important to check the inhibitor concentration after installation system modification and at every service in accordance with the inhibitor manufacturer s instructions Test kits are available from inhibitor stockists 5 For information or advice regarding any of the above contact Technical Enquiries 0844 871 1555 11 Boiler Air Vent Fig 9 22mm O pen Vent Boiler Air Vent Flow Return Fig 10 Typical Low Head Installation cart 22mm A oe O pen Vent Boiler Air T 45 Vent 15mm 400mm Cold Min Head Feed 150mm Max Return If Conditions Require This System Possible Fig 11 22mm Feed amp Vent Pipe Boiler Air Vent a Air Separator Flow Return Fig 12 Alternative Low H ead Installation 12 Baxi Heating UK Ltd 2011 Flow 6 0 System Details Pipework 1 The sizes of flow and return pipes from the boiler should be determined by normal methods according to the requirements of the system 2 The connection tails for the boiler are 28mm diameter The 28mm section of the tails can be cut back to 22mm if
15. I I Condensate Overheat i Trap Thermostat j sly i I I bk 325 Vdc Fico bk DCF i Spark Flame an Switch Electrode Detection Gas Electrode w Valve Flow Overheat bY bk Thermostat Electrical Filter Earths not shown to aid clarity of diagram Boiler Connection 4 Core Cable n paps CO anq quaurwweg LOO P L Z Key To W iring Colours b Blue r Red bk Black g Green w White g y Green Y ellow br Brown op Opaque gy Grey y Yellow o Orange v Violet 34 Baxi Heating UK Ltd 2011 11 0 Electrical Illustrated W iring Diagram Flow Thermistor gt DN Flame Detection Electrode PTN Layout of PCB Pins ia il AIS Fan Overheat Thermostat Flow Overheat Thermostat W iring Key b Blue bk Black br Brown r Red w White gly Green Yellow g Green gy Grey op Opaque y Yellow Baxi Heating UK Ltd 2011 35 Central Heating Control Knob No OFF Position Reset Button Mains On Green Light Burner On Green Light Flame Failure Red Light Flue Sampling Point Manual Air Vent Gas Service Cock O pen Fig 34 MD Cy ZF y Q WY Los Fig 36 Turn the Central Heating Control Knob clockwise to increase or anticlockwise to decrease the boiler flow temperature The
16. PCB Control and Fan Assembly are 325 Vdc Isolate system controls before access 1 Loosen the screw holding the injector pipe into the venturi 2 Remove the electrical connections to the fan and protection sensor on the fan 3 Remove the wing nuts securing the fan to the base of the combustion box 4 Lower the fan and remove 5 If changing the fan remove the screws securing the venturi and fan protection sensor bracket noting the positions of the injector opening and sensor bracket fix them to the new fan 6 Fit the new fan and reassemble in reverse order The injector pipe condensate trap and gas valve can be changed after the removal of the fan 45 15 0 Changing Components The removal of the fan is necessary to enable the changing of the injector pipe condensate trap and gas valve see section 13 6 Injector Pipe Fig 53 1 Remove the injector pipe by pulling out from the O ring joint in the gas valve 2 Fit the new injector pipe and reassemble in reverse order Injector Pipe IRAE Gas Valve Fig 53 IMPORTANT After replacing the valve the CO2 must be checked as detailed in Section 14 1 4 to 14 1 6 Only change the valve if a suitable calibrated combustion Gas Valve Securing Screws analyser is available operated by a competent person see Section 14 1 3 1 Isolate gas supply and disconnect the gas tap by remo
17. Reset Button should extinguish the Flame Failure Light and restore normal operation This indicates that there is electricity to the Boiler This indicates that the Burner has fired up and is heating your system If Flame Failure Light is ON Press the Reset Button If Flame Failure occurs persistently consult your Installer or Service Engineer Condensate Pump This indicates that the Condensate Pump is running Green Light 36 Baxi Heating UK Ltd 2011 The pump ONLY runs when the condensate reservoir is full Fig 36a 12 0 Commissioning the Boiler Commissioning the Boiler WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate at supply before access 1 Reference should be made to BS EN 12828 amp 14336 when commissioning the boiler 2 At the time of commissioning complete all relevant sections of the Benchmark Checklist at the rear of this publications 3 Flush the whole system using a suitable flushing agent see Section 6 2 and vent the radiators Check for water leaks 4 Refill the system with inhibitor following the inhibitor manufacturer s instructions and BS 7593 Code of Practice for Treatment of W ater in Domestic Hot W ater Central H eating Systems see Section 6 2 5 Complete the label supplied with the inhibitor and attach to the inside of the boiler case D etail of system treatment should be added for future reference 6 Turn the gas supply on and purge according to in GB
18. Site Requirements Location NOTE Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue This should be taken into account when siting the flue terminal 1 The boiler must be fitted on a suitable flat and level surface capable of supporting the weight Any wall behind the boiler must be at 90 to the floor to allow case top cover to fit correctly 2 The flue must pass through an outside wall or roof and discharge to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply 3 The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i e garage or outhouse 4 The boiler incorporates a frost protection device This will only protect the boiler To ensure protection of the system pipework and components it is recommended to incorporate an appropriate device within the system controls 5 If the boiler is fitted in a room containing a bath or shower it can only be fitted in Zone 3 Figs A amp B shows zone dimensions for a bathtub For other examples refer to the Current I E E W iring Regulations Reference must be made to the relevant requirements In GB this is the current E E W iring Regulations and Building Regulations In IE reference should be made to the current edition of l S 813 Domestic Gas Installations and the current ETCI rules 6 If the boiler is
19. amp 20kQ Plug in thermistor leave a 8 way connector unplugged W iring from PCB to Is resistance at D between thermistor faulty Viewed from 0 5kO amp 20kQ W ire Entry end YES Replace PCB 56 Baxi Heating UK Ltd 2011 CONDENSATE PUMP Reset boiler and add approx 1 litre tap water to the condensate system via the flue or Does the pump motor run as the condensate level rises NO YES NO As the pump motor runs does the condensate flow to drain YES NO condensate flow rate at least 1 8 l min and run time less than 3 minutes YES NO Does pump motor stop as level in reservoir falls YES O peration correct Baxi Heating UK Ltd 2011 Condensate pump over level switch activated pump reservoir level too high resulting in ignition lockout Mechanical fault on float linkage or switch Mechanical fault on pump or impellor NO YES If fault cannot be rectified replace level switch or pump assembly NO Condensate pump outlet back check valve blocked or seized shut YES If fault cannot be rectified replace pump assembly 17 0 Fault Finding Lights x On ODA O O Q Condensate pump level switch activated for longer than 3 minutes boiler locks out Boiler will try to relight 4 times in 5 minutes 5Vdc at A No replace PCB 5V
20. by means of a temporary connection between the primary circuit and a supply pipe provided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment Your attention is drawn to for GB Guidance G24 2 and recommendation R24 2 of the W ater Regulations Guide for IE the current edition of 1S 813 Domestic Gas Installations 5 MAKE UP SYSTEM A method of replacing water lost from the system should be provided either by means of a make up vessel of not more than 3 litres 5 pints capacity mounted above the highest point of the system or by re pressurisation of the system 6 VENTING A method of venting the system during filling and commissioning must be provided by fitting automatic air vents or by venting manually 7 HOT WATER STORAGE The hot water storage vessel must be of the indirect coil type 8 COMPONENTS All components used in the system must be suitable for operation at 110 C 230 F and at the pressure allowed by the safety valve Baxi Heating UK Ltd 2011 P_Zone2 Window 4 Recess W indow Recess Zone 2 Fig B In GB Only W indow Recess Zone 2 225m ee ee ee 0 6 m In GB Only Ceiling Outside Zones 7 0
21. is 150m NOTE Each 1m of flue duct should be calculated as 2m Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 135 bend 0 5m 93 bend 10m Twin Flue Pipe 135 bend air duct 13m 135 bend flue duct 2 6 m 90 bend air duct 48m 90 bend flue duct 9 6 m IMPORTANT All flue systems must be securely supported at least once every metre Suitable pipe supports are available as accessories The total equivalent length for this example is 17 2 34 4 51 6 metres Equivalent N of Sub total Length Value fittings pipes 1m extension 135 bend 91 5 bend Equivalent Length Value 1m extension 135 bend 91 5 bend Equivalent Length Flue D uct 34 4m 21 22 Baxi Heating UK Ltd 2011 8 0 Flue Options Flue Accessories Key Accessory Size FLUE GROUP B Concentric Flue System 110mm diameter Al Horizontal Flue Terminal 850mm A Horizontal Flue Terminal incl elbow B Flue Extension 1000mm 500mm 250mm ue Bend 93 ue Bend pair 135 ipe Support 110mm ertical Flue Boiler Adaptor ue Terminal Deflector naAacuoun Set So Sn Sn FLUE GROUP P Twin Flue System 80mm diameter E Flue Extension pair 1000mm 500mm 250mm F Flue Bend pair 90 Flue Bend 2 pair 135 J Vertical Flue Boiler Adaptor Kit W Pipe Support pair 80mm FLUE GROUP B P Vertical Flue Kits
22. made Plug Trap to Condensate Fig 54 Pump Inlet Pipe 7 Prime the condensate trap fill first chamber check for leaks 46 Baxi Heating UK Ltd 2011 see Section 8 5 Combustion Box Door Panel purmer Support gt Bracket x i Return Connection Fig 57 Fig 56 Fig 58 Heat Exchanger Manifold Heat Exchanger Assembly seese Fig 59 Baxi Heating UK Ltd 2011 15 0 Changing Components The burner and heat exchanger can be changed after removal of the combustion box door To change the heat exchanger the fan and burner must be removed first see section 13 6 and 13 10 1 Remove the combustion box door by removing the four securing screws Fig 55 IMPORTANT On refitting the combustion box door check the condition of the combustion box door seals toma Burner Fig 56 1 Remove the two screws securing the burner to the base of the combustion box 2 Remove the burner carefully from the combustion box base 3 Check the burner seal on the heat exchanger base replace if necessary Fit the new burner and reassemble in reverse order sie Heat Exchanger 1 Drain the boiler see section 13 1 paragraph 2 amp 3 2 Remove all components in the base of the airbox 3 Undo the screws on the support bracket Remove the
23. 0 70 Flue Extension 250mm 241692 Flue Extension 500mm 241694 Flue Extension 1000mm Use two kits for 2M etc 241695 Flue Bend x 2 45 Reduce overall length of flue by 0 5m when fitting this bend 241689 Flue Bend 93 Reduce overall length of flue by 1m when fitting each bend 241687 VERTICAL FLUE Vertical Flue Terminal 242802 Vertical Flue Adaptor 5106888 See Section 7 12 for more flue option details Integral Twin C hannel Timer 5117696 41 Condensate Pump will operate as necessary 3 1 9 Flow temperature less than set point System Pump Running and Flow switch made YES YES Ignition done 5 second and less than 5 Fan Pre Purge attempts made 5 second Ignition Period Flame Detected Ignition done and 5 attempts made YES Ignition Lockout All TRVs shut or Flow temperature greater than set point 5 second Fan Post Purge All TRVs shut down 3 minute Anti cycle 8 Baxi Heating UK Ltd 2011 3 0 Boiler O peration Boiler O peration 1 Switched Live O n W hen switched live is supplied to the boiler and the flow temperature is less than the set point the sequence below commences 2 Flow Switch After 10 seconds if the flow switch has made then fan pre purge occurs After 10 seconds if the flow switch has not made then anti cycle occurs 3 Fan Pre Purge The flow switch is made and the fan is on while the spark generator a
24. 0 supplied in kit 3 x 1 metre Extensions 1 x 93 Elbow 2 x 45 Elbow Total 700 1 metre 3 metres 1 metre 1 metre 0 5 metres each 6 metres After consulting the table in Example 3 it can be determined that the concentric flue could be up to approximately 3 25 metres long 9 0 Plume Displacement General Fitting N otes P D K 1 Cut a hole in the external wall which the horizontal This section of the concentric flue assembly will pass through flue MUST be horizontal 2 W hen completed the terminal must be at least 2 metres Min 2 metres i above ground level Fig E 3 Measure and cut to size the concentric assembly and any extensions that are being used 4 Insert the concentric assembly through the hole from outside the building and mark the position of the flue trim securing holes Min 0 3 metres 5 Drill and plug the wall to accept the flue trim securing screws and re insert the concentric assembly through the wall 6 Connect any extensions that are being used to the concentric assembly Engage the extension or concentric assembly in the boiler flue elbow 7 Fit the boiler flue elbow to the boiler top panel ensuring the gasket is in place Fig F Fig E Ensure that the conce
25. 2 Heat O utput P Condensing 40 C Mean W ater Temp Max Min kW 32 61 10 0 Max Gas Rate After 10 Mins kW Input 33 76 2H G20 20mbar m hr 34 Inlet Pressure at Gas Valve N atural Gas Min 18 1 mbar Max 22 5 mbar see Section 10 1 Injector Natural Gas Diameter 6 5mm CO CO Ratio 0 004 NO Class 5 SEDBUK Declaration SAP 2005 Seasonal Efficiency model is 90 9 This value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated has been certified by 0087 Baxi Heating UK Ltd 2011 4 0 Technical Data Horizontal Flue Terminal Diameter 110mm Dimensions Projection 150mm Connections Gas Supply 15mm Central H eating Flow 28mm Central H eating Return 28mm Condensate Drain Pump 10mm o d O utercase Dimensions Casing H eight 850mm Casing W idth 390mm Casing Depth 520mm Minimum Clearances For unventilated compartments see Section 7 2 Both Sides Above Casing Above Casing Under fixed worktop It is recommended that any worktop is removable Front For Servicing Front In O peration 5mm 15mm 25mm 500mm 5mm W eights Packaged Boiler Carton Packaged Flue Kit Installation Lift W eight Installed W eight dry kg 495 36 375 445 Recommended System Temperature Drop Condensing 20 C Electrical Supply 230V
26. 798 Installation of gas fired hot water boilers BS 5440 Part 1 Flues BS 5440 Part 2 Ventilation BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems In IE the following Codes of Practice apply Standard Scope LS 813 Domestic Gas Installations The following standards give valuable additional information BS 5546 Installation of hot water supplies for domestic purposes BS EN 12828 Heating systems in buildings BS EN 12831 Heating systems in buildings Calculation of load BS EN 14336 Installation amp commissioning of water based heating systems BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems Baxi Heating UK Ltd 2011 Section Page 1 0 Introduction 6 2 0 General Layout 7 3 0 Boiler Operation 8 4 0 Technical Data 9 5 0 Dimensions and Fixings 10 6 0 System Details 11 7 0 Site Requirements 15 8 0 Flue Options 20 9 0 Plume Displacement 25 10 0 Installation 29 11 0 Electrical 34 12 0 Commissioning the Boiler 36 13 0 Completion 38 14 0 Servicing the Boiler 39 15 0 Changing Components 42 16 0 Short Parts List 49 17 0 Fault Finding 50 Benchmark Checklist 58 Facia Securing Screws O ptional Integral Timer Position of
27. Inlet Temperature Hot water has been checked at all outlets Yes E Temperature C Water Flow Rate __ limin CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted ALL INSTALLATIONS If required by the manufacturer record the following co OR CO C ppm OR CO CO Ratio pe The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Ye Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified
28. Label Fig 1 Case Securing Screws Air Box Door Fig 2 Data Badge 6 Baxi Heating UK Ltd 2011 1 0 Introduction Description 1 The Potterton Gold FSB 30 HE is a gas fired room sealed fan assisted condensing central heating boiler 2 The maximum output of the boiler is 30 18 kW Non Condensing 32 61 kW Condensing 3 The boiler is designed for use on N atural Gas G 20 only 4 The boiler is suitable for fully pumped open vented and sealed systems providing heating and hot water 5 A label giving details of the model serial number and Gas Council number is situated on the rear of the drop down facia panel Fig 1 6 The boiler data badge is positioned on the air box door Fig 2 7 The boiler is intended to be installed in residential commercial light industrial EM C environments on a governed meter supply only 8 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit part no 236921 Important Information Man made mineral fibre Some component parts of this boiler insulation pads gaskets and rope seals are manufactured from man made mineral fibre Prolonged or excessive exposure to this material may result in some irritation to the eyes skin or respiratory tract It is advisable to wear gloves when handling these items e Irritant dust will only be released from the items if t
29. You can rely on POTTESJON Installation amp Service Instructions Gold FSB 30 HE Floor Standing Condensing Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Baxi Heating UK Ltd 2011 Natural Gas Potterton Gold FSB 30 HE G C No 41 592 32 The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information Baxi Heating UK Ltd 2011 All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means or stored in any retrieval system of any nature including in any database in each case whether electronic mechanical recording or otherwise without t
30. and only used in a suitably ventilated location In GB the installation must be carried out by a Gas Safe Registered Installer It must be carried out in accordance with the relevant requirements of the e Gas Safety Installation amp Use Regulations e The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations N orthern Ireland e The W ater Fittings Regulations or W ater Byelaws in Scotland The Current I E E W iring Regulations W here 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 S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation All systems must be thoroughly flushed and treated with inhibitor see section 6 2 Codes of Practice most recent version should be used In GB the following Codes of Practice apply Standard Scope BS 6891 Gas Installation BS 5482 Part 1 Butane amp Propane Gas Installation BS 5546 Installation of hot water supplies for domestic purposes BS EN 12828 Heating systems in buildings BS EN 12831 Heating systems in buildings Calculation of load BS EN 14336 Installation amp commissioning of water based heating systems BS 6
31. as follows a Disconnect the electrical leads to the fan component protection sensor Fig 42 b Loosen the screw retaining the gas injector pipe at the venturi Fig 42 c Undo the two wing nuts to disconnect the fan Fig 42 d Remove the fan and disconnect the electrical supply to it Fig 42 Injector Pipe e Remove the gas injector pipe from the gas valve en push fit Fig 42 f Remove the condensate trap drain plug and place a vessel underneath to catch the condensate care should be taken as this could be hot The condensate drain pipe may be removed to increase access Injector Pipe Retaining Screw g Undo the condensate trap securing nut lock nut and the condensate drain pipe Remove the condensate trap and disconnect the sensor leads Fig 43 Clean the trap and refit the drain plug h Remove the two screws securing the burner and remove the burner Visually inspect the internal burner baffle for obstruction check seal around baffle for Leads cracks damage Clean with a soft brush Protection ON i Sensor Leads i A Electrical Supply Condensate H i Loosen the two screws retaining the heat exchanger Trap support bracket and slide to the left to remove Fig 44 Fig 42 W ing N uts Lock N ut s at O Service Drain j Remove the four screws securing the heat 7 Plug exchanger combustion box base and with
32. d in the flue Fig 28 8 Engage the flue into the flue elbow using soap solution to ease the engagement ensuring the flue terminal is positioned as shown Fig 29 9 Place the gasket over the flue exit on the boiler 10 Slide the flue assembly through the hole in the wall 11 Engage the elbow on to the flue connection on top of the boiler Secure with the four screws supplied in the kit 12 Make good between the wall and air duct outside the building ensuring the 3 drop between the terminal and elbow 13 The flue trim should be fitted once the installation is complete and the flue secure Fig 30 Apply a suitable mastic to the inside of the trim and press against the wall finish making sure the brickwork is dust free and dry 14 If necessary fit a flue plume deflector kit and or terminal guard see Sections 7 6 amp 8 8 Flue Trim Shaded Areas indicate Recommended Handling Points Baxi Heating UK Ltd 2011 31 Min radius 100mm Point A Boiler Fig A Condensate Pipe Direct Connect Fitting Fig B Max Head 3 metres Gravity Drain min fall 3 N ote The point of discharge from the pumped length of condensate pipe point A must not be below the level of the pump whether discharging direct into a drain or into an additional gravity drain Alternative H orizontal Discharge 10mm PVC Pipe 8 5mm I D Sec
33. dc at B No check wiring 240V acrossC amp D No replace level switch Goto diagram for connections to check Is motor resistance across C amp D approx 40 ohms No replace pump assembly Condensate pipe blocked or kinked or outlet blocked or frozen at drain YES Rectify fault replacing pipe if necessary Condensate pipe NO has high resistance too long or restricted head greater than 3 metres YES Rectify fault replacing or re routing pipe if necessary Mechanical fault on float linkage or level switch After 3 mins boiler will lock out If fault cannot be rectified replace level switch or pump assembly Pump motor or impellor worn replace pump assembly Condensate Pump Assembly Condensate Level Switch Condensate Condensate Pump Over Level Switch Motor a Gi 57 This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer Name Telephone Number Address Boller Make sind Modi OEE Commis
34. draw the Trap to Condensate z base Central nenigtian Panel Pump Inlet Pipe k Lower the central insulation panel and check condition Fig 44 Replace the lower insulation pad if necessary Ensure the heat exchanger fins are clear of any Burner obstruction n m Check condition of all seals Important Pay Combustion ga particular attention to the condition of the Box Base E combustion box door seals Heat Exchanger f n Reassemble in reverse order and check for leaks Support Bracket 8 Check the operation of the condensate pump and drain pipework see Section 10 1 9 Check CO CO2 ratio at flue sampling point Fig 41a See section 4 0 8 Tei Loy Combustion Box Base Securing Screws Burner Securing Screws 10 Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user 41 Fig 44 Baxi Heating UK Ltd 2011 Fig 45 Heat Exchanger Manifold 0 ji Pipe Access RI Panel Thermostat Black Fig 46 42 Baxi Heating UK Ltd 2011 15 0 Changing Components Changing Components amp Preparation WARNING The PCB Control and Fan Assembly are 325 Vdc Is
35. e boiler can be fitted at this stage and secured with the spring clips The flow and return connections are identified on the boiler rear panel The flow pipe incorporates a manual air vent 2 Note that the seal is made by use of an O ring therefore some pipe movement will be evident even though a water tight seal has been achieved Excessive force could result in damage to the connection 3 Make all soldered joints before connecting the tails to the boiler to avoid damaging the O rings 4 Refit the pipe access panel Making the Gas Connection 1 The connection to the boiler is a 15mm tail on the gas service cock The tail protrudes through the boiler rear panel and is protected by a transit bracket which may be removed to aid connection see Fig 22 2 If solder joints are being used for the gas connection remove the gas tap from the valve as excessive heat may damage the O ring seal Priming the Condensate Trap 1 Using a funnel and tube carefully pour approximately 1 cupful 250ml of tap water into the flue products exhaust at the terminal or flue elbow sampling point to ensure a seal is made in the trap 29 W all Thickness At least 1 5 Edge of Boiler Case to W all W all Thickness Fig 26 Z Side Exit X Rear Exit Inner Flue Support Bracket 30 Baxi Heat
36. e boiler combustion circuit and relevant seals as described in Section 14 2 e The operational gas inlet pressure as described in Section 12 2 1 to 12 2 3 and the gas rate as described in 12 2 4 e The combustion performance as described in C heck the Combustion Performance 14 1 4 to 14 1 6 below 3 Competence to carry out Checking Combustion Performance B S 6798 Specification for Installation amp Maintenance of Gas Fired Boilers not exceeding 70kW advises that e The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results e The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN 50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Check the Combustion Performance CO COzratio 4 Set the boiler to operate at maximum rate as described in Section 12 2 5 Remove the cap from the flue sampling point insert the analyser probe and obtain the CO CO zratio This must be less than 0 004 6 If the combustion reading CO CO ratio is greater than this and the integrity of the complete flue system and combustion circuit seals has been verified and the in
37. e flue elbow should be 27 5mm eV to incorporate the 1 5 fall in the flue ss ______At least from the terminal to the elbow It is 15 especially important to consider this when fitting the boiler under a work top N Y Flue length Y Clearance X up to 1m 27 5mm 1m 2m 55mm 2m 3m 82 5mm 3m 4m 110mm Fig 8 10 Baxi Heating UK Ltd 2011 Baxi Heating UK Ltd 2011 6 0 System Details W ater Circulating Systems 1 The boiler is suitable for use with open vent fully pumped systems and sealed systems The following conditions should be observed on all systems e The static head must not exceed 30m of water e The boiler must not be used with a direct cylinder e Drain cocks should be fitted to all system low points All gas and water pipes and electrical wiring must be installed in a way which would not restrict the servicing of the boiler e Position isolating valves as close to circulating pump as possible Treatment of W ater Circulating Systems 1 All recirculatory water systems will be subject to corrosion unless they are flushed and an appropriate water treatment is applied To prevent this follow the guidelines given in BS 7593 Treatment of W ater in Domestic Hot W ater Central H eating Systems and the treatment manufacturers instructions 2 Treatment must involve the use of a proprietary cleanser such as Sentinel X 300 or X 400 or
38. e fully pumped and must provide independent temperature and time control to both the heating and hot water circuits and have a boiler and system pump interlock 3 The boiler should be controlled so that it operates on demand only W here it is proposed to effect control by thermostatic radiator valves a room thermostat should also be provided to switch off the boiler when there is no demand for heating 13 3 Litre ea Vent q Filling Safet Pressure Point atety Gauge Bea Valve Pump lt Expansion Radiator Vessel Circuit Low Point Max Boiler Flow Fig 13 Temp 82 C Method of determining minimum expansion vessel volume for sealed systems Multiply Total Initial System W ater Content O f Pressure Bar System By Litres Vessel C harge Pressure Bar Example System Volume 75 litres Vessel Charge Pressure 1 0 bar Initial System Pressure 1 5 bar Then 75 x 0 152 114 litres Expansion Vessel Volume Table 1 NOTE W here a vessel of the calculated size is not obtainable then the next available larger size should be used Double Stop Check Stop Valve Valve Valve Mains y x Inlet 7 A Temporary CH Hose Return Fig 14 14 Baxi Heating UK Ltd 2011 6 0 System Details Sealed Systems Fig 13 1 SAFETY VALVE A safety valve complying with the requirements of BS 6750 Part 1 must be fitted close to the boiler on the flow pipe by means of a horizontal or verticall
39. efficiency of the boiler a plume of D Below gutters soil pipes or drain pipes 25 water vapour will be discharged from the flue This should E Below eaves 25 be taken into account when siting the flue terminal F Below balconies or car port roof 25 G From a vertical drain pipe or soil pipe 25 1 The following guidelines indicate the general requirements H From an internal or external corner i 25 115 for siting balanced flue terminals Above ground roof or balcony level 300 For GB recommendations are given in BS 5440 Pt 1 From a surface or boundary line facing a terminal 600 For IE recommendations are given in the current edition of I S K From a terminal facing a terminal Horizontal flue 1200 813 Domestic Gas Installations From a terminal facing a terminal Vertical flue 600 L From an opening in carport e g door window 2 If the terminal discharges onto a pathway or passageway into the dwelling 1200 check that combustion products will not cause a nuisance and Vertically from a terminal on the same wall 1500 that the terminal will not obstruct the passageway N Horizontally from a terminal on the same wall 300 3 W hen siting the flue take into consideration the effect the R From adjacent wall to flue vertical only 300 plume of water vapour may have on neighbours S From an adjacent opening window vertical only 1000 T Adjacent to windows or openings on pitched and flat roofs 600 4 Adjacent surfaces close to the
40. ermistor and the safety thermostat 2 Remove the pipe access panel and disconnect the electrical connections from the sensor 3 Remove the sensor from the pipe 4 Fit the new thermistor or safety thermostat and reassemble in reverse order Support Bracket Clip O ver Level Switch Fig 47a Level Switch Baxi Heating UK Ltd 2011 Pipe Access Panel Condensate Pump Cover Removed 15 0 Changing Components Flowswitch Fig 47 1 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 Remove the pipe access panel and remove the securing clip from the O ring joint between the flow pipe and the system Undo screws on support bracket 3 Remove the securing clip from the O ring joint between the flow pipe and the flowswitch 4 Remove the two screws securing the flow switch to the boiler 5 Disconnect the inline electrical connection and remove the flowswitch 6 Fit the new flowswitch and reassemble in reverse order 7 Recommission the boiler and check the inhibitor concentration see Section 6 2 and 10 1 Condensate Pump Complete Fig 47a 1 Remove the pipe from the trap to the pump inlet and disconnect the electrical plug 2 Lift the pump off the support studs and ease it forwards Release the snap fit clip and disconnect the condensate outlet pipe 3 Connect the condensate outlet pipe t
41. flue terminal may need U Below windows or openings on pitched roofs 2000 protection from the effects of condensation Alternatively a flue deflector kit part no 248167 is available Table 2 a In addition the terminal should be no nearer than 150 mm to an 5 For installation of the flue into an internal corner at the opening in the building fabric formed for the purpose of accommodating 25mm dimension the flue plume deflector kit part no 248167 a built in element such as a window frame See BS 5440 Pt 1 must be fitted N OTE The distance from a fanned draught boiler terminal 6 Reduction to the boundary is possible down to 25mm but installed parallel to a boundary may not be less than 300mm the flue plume deflector kit part no 248167 must be fitted in accordance with the diagram below unless the flue deflector ae kit is used see 7 8 6 opposite 7 If a terminal is less than 2 metres above a balcony above l omin i ground or above a flat roof to which people have access then Terminal a suitable terminal guard must be provided Assembly eh F s 8 If required a suitable terminal guard part no 248484 is d r available from Potterton for use with the flue deflector See gt 4 also Section 8 8 U i 9 For fitting under low soffits and eaves the Plume i Displacement Kit or Flue D eflector Kit is recommended Top View Rear Flue 1 IMPORTANT Fig 16a Only ONE 25mm clearance is allowed per installation e Under car ports
42. he 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 H eating UK Limited Brooks House Coventry Road W arwick CV34 4LL Full acknowledgement of author and source must be given W ARNING Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages C 0 0 8 6 recommended Baxi Heating UK Ltd 2011 Building Regulations and the Benchmark Commissioning Checklist Building Regulations England amp W ales require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1 January 2006 The Health amp Safety Executive operates the Gas Safe Register a self certification scheme for gas heating appliances These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the
43. hey are broken up or subjected to severe abrasion In these instances a suitable dust mask and goggles should be worn e Always thoroughly wash hands after installation servicing or changing components W hen disposing of any items manufactured from man made mineral fibre care must be exercised e If any irritation of the eyes or severe irritation of the skin is experienced seek medical attention Baxi Heating UK Ltd 2011 16 L yS ON D wy 2 0 General Layout Layout Figs 3 4 5 amp 6 Or OSG et ON se ee o PP e e PP PP PP BP 22 O00 UE Oy OP oe am eS Condensate Pump Flue Elbow supplied in std flue kit H eat Exchanger Burner Air Box Fan Protection Thermostat Black Fan Assembly Condensate Trap PCB Housing Assembly Gas Tap Gas Air Ratio Valve Flow Pipe Connection eturn Pipe Connection ow Temperature Safety Thermostat Black ow Temperature Thermistor Red ow Switch dry fire protection osition of O ptional Integral Timer W iring R F F F P P ipe Access Panel Manual Air Vent 1108 Concentric Flues amp O ptional Extras ya ZA 4 wy M ol KIT PART N Standard Flue Kit 850mm inc elbow 236921 Extended Flue Kit 1 75M inc elbow 5111457 Flue Plume Deflector Kit 248167 Terminal Guard suitable for use with above 248484 FLUE EXTENSION KITS 11
44. in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point is in accordance with BS 6798 amp B S 6891 3 Ensure that this inlet pressure can be obtained with all other gas appliances in the property working Measure the Gas Rate 4 W ith any other appliances amp pilot lights turned O FF the gas rate can be measured It should be as shown in Section 4 0 Technical D ata 5 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the boiler and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 6 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with IS 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist Inlet Gas Pressure Test Point Baxi Heating UK Ltd 2011 37 O utercase Securing N Screws Facia Securing Screws Fig 38 38 Baxi Heating UK Ltd 2011 13 0 Completion Fitting The Case Panels amp Facia 1 Refit the case top panel and front door securing with the screws previously removed Fig
45. ing UK Ltd 2011 10 0 Installation Fitting the Standard Flue IMPO RTANT The flue should always be installed with at least 1 5 fall from terminal to elbow to allow condensate to run back to the boiler 1 The standard flue is suitable for lengths 270mm minimum to 800mm maximum measured from the edge of the flue elbow outlet Rear Flue maximum wall thickness 575mm Side Flue maximum wall thickness 535mm 2 For rear exit measure the wall thickness Fig 26 and to this dimension add 270mm This dimension to be known as X ie X wall thickness 270 3 Take the flue and mark off X from the terminal end as indicated in the diagram Fig 27 4 For side exit measure the distance from the edge of the boiler case to the inner face of the wall Fig 26 and to this dimension add the wall thickness 280mm This dimension to be known as Z ie Z case to wall wall thickness 280 5 Take the flue and mark off Z from the terminal end as indicated Fig 27 Before cutting check your dimensions 6 The flue tubes are fixed together Cut through both tubes whilst resting the flue on the semi circular packing pieces Deburr both tube ends NOTE W hen cutting ensure the cut does not interfere with the inner flue support bracket Fig 27a 10 0 Installation Fitting the Standard Flue Cont Inner Flue Support Bracket 7 Ensure the inner flue support bracket is positione
46. let gas pressure and gas rate are satisfactory either e Perform the Annual Servicing Inspection Section 14 2 amp re check e Replace the gas valve Section 15 8 amp re check 39 14 0 Servicing the Boiler Annual Servicing Inspection WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate system controls before access 1 Ensure that the boiler is cool 2 Remove the facia and front door panel 3 Release the four 1 4 turn screws securing the air box door panel and remove the panel Fig 39 4 Disconnect the three leads from the terminals Fig 40 5 Undo the four screws securing the combustion box door and remove the door Fig 41 6 Visually check for debris damage and clean or replace if necessary the following a a Burner Air Box Door Panel Fig 39 b Heat exchanger fins c Fan compartment Check also for condensate leaks d Insulation e Door seals Important Pay particular attention to the condition of the combustion box door seals f Electrodes g The condensate trap h The condensate pump i Top of heat exchanger Lead Terminals Fig 40 Combustion Box Door Panel 40 Baxi Heating UK Ltd 2011 14 0 Servicing the Boiler Annual Servicing Inspection C ont Fl ling Point ue sampling Poin 7 To clean the heat exchanger and burner proceed
47. levant ACS modules is deemed competent In IE this must be carried out by a competent person as stated in I S 813 Domestic Gas Installations The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty In GB this could also infringe the Gas Safety Installation and Use Regulations W arning Check the information on the data plate is compatible with local supply conditions All Gas Safe registered engineers carry an ID card with their licence number and a photograph You can check your engineer is registered by telephoning 0800 408 5500 or online at www gassaferegister co uk The boiler meets the requirements of Statutory Instrument The Boiler Efficiency Regulations 1993 N 3083 and is deemed to meet the requirements of Directive 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purpose of Regulation 5 certified by Notified Body 0087 Product Production certified by Notified Body 0086 For GB IE only 4 Baxi Heating UK Ltd 2011 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
48. n eene gt Servicing Instructions and BS5440 Pt 1 It is N OT upwards necessary to fit a terminal guard over the air inlet or the plume outlet Fig B Baxi Heating UK Ltd 2011 25 0 R o 70 Exhaust metres amp 0 i 2 3 4 Concentric 70 110 Flue metres Example 1 Flue Lengths N ot Permissible 30 28 26 24 22 20 16 70 Exhaust metres D Example 3 Flue Lengths 70 Exhaust oncentric 70 110 MUST be installed horizontally Additional Accessories A 93 Elbow 5117381 5117382 5117380 B 45 Elbow Pair C 1 metre 60 Extension 26 Baxi Heating UK Ltd 2011 N R amp 70 Exhaust metres o n FR OD amp 0 1 2 3 4 Concentric 70 110 Flue metres Example 2 i i Flue Lengths O K 2 3 4 Concentric 70 110 Flue metres OK Support Bracket 7 Us 45 Elbow lt 93 Elbow Te 1 metre Extension Diviis 1 metre supplied in kit Flue Concentric Flue Fig D 9 0 Plume Displacement Determining Permissible Lengths P D K In the graph the solid line diagonal represents the relationship between the concentric flue assembly and any extensions and the 70 exhaust and any extensions or additional bends Example 1 N ot Permissible If for instance a concentric length of 3 25 metres was required and the 70 exhaust needed to be 10 metres the graph
49. nd gas valve are off After 5 seconds ignition occurs 4 Ignition The flow switch is made fan spark generator and gas valve are on If a flame is detected then burner on occurs If a flame is not detected within 5 seconds and less than 5 ignition attempts have been made then fan purge occurs If a flame is not detected within 5 seconds and 5 ignition attempts have been made then ignition lockout occurs 5 Burner On The flow switch is made fan and gas valve are on while the spark generator is off Flow temperature is controlled by varying the fan speed and thereby the gas rate to achieve optimum operation If the flow temperature is greater than the set point or the TRVs all shut down then fan post purge occurs 6 Fan Post Purge The fan is on while the spark generator and gas valve are off After 5 seconds if the TRVs are shut down then anti cycle occurs 7 Anti cycle The fan spark generator and gas valve are off 8 Ignition Lockout The fan spark generator and gas valve are off The boiler can only be reset by manually using the reset button 9 Condensate Pump Condensate accumulates in a reservoir within the pump assembly The pump may run at any time independent of boiler operation to discharge the condensate to drain Appliance Type C3 C33 Appliance Category CAT I oy Heat Input Q Gross Max Min kW 33 76 103 Heat O utput P N on Condensing 70 C Mean W ater Temp Max Min kW 30 18 9
50. nto the new PCB Fig 48 2 Remove the top right hand securing screw and swing out the PCB housing Remove the PCB cover and disconnect the electrical plugs noting their positions 3 Remove the screw securing the PCB to the housing The PCB can be removed from the housing 4 Ensure that the two jumpers are fitted to the new PCB as shown Fig 49 5 Reconnect the plugs fit the new PCB to the housing and reassemble in reverse order Fig 50 Combustion Box Door Spark Earth Fig 51 Injector Pipe ws Injector Screw y O pening l Gere Fan Pro tectio n Sensor Venturi Electrical Connections Fig 52 Baxi Heating UK Ltd 2011 W ing N uts 15 0 Changing Components The fan and venturi gas valve injector pipe condensate trap fan protection sensor spark and sensing electrodes can be accessed and changed on the removal of the airbox door panel 1 Remove the airbox door panel by loosening the four 1 4 turn screws Fig 50 Spark and Sensing Electrodes Fig 51 1 Disconnect all three leads from tabs Spark O paque cable Earth Green Yellow cable Sensing W hite cable 2 Remove the two screws securing each of the electrodes to the combustion box door and remove the electrodes 3 Fit the new electrodes and new gasket as required and reassemble in reverse order Fan Fig 52 WARNING The
51. ntric assembly is horizontal and that the external air inlet is to the bottom Any extensions should fall back to the boiler 8 Use suitable brackets to support the concentric assembly and any extensions and make good inside and outside Secure the flue trim to the wall 9 The 70 exhaust can now be fitted to the spigot at the terminal end 10 If it is necessary to shorten the 70 exhaust or any of the extensions the excess material must be cut from the Fig F plain end of the pipe 11 Determine the position of the 70 exhaust and mark on the wall a suitable position for the support bracket D rill and plug the wall If extensions are being used a support bracket is supplied in each kit 12 Engage the M6 threaded part of the mounting bolt in the boss on the support bracket U sing the bracket for leverage screw the mounting bolt into the plugged hole until the bracket is secure and level Fig G 13 Slacken the two screws securing the retaining strap to the bracket and pivot the strap aside to allow fitting the 70 exhaust 14 Complete the installation of the 70 exhaust securing in the brackets Fit the 93 elbow and plume outlet Ensure the plume outlet is at least 45 to the wall and that the peak is uppermost Fig G 15 Continue with installation and commissioning of the boiler Baxi Heating UK Ltd 2011 27 9 0 Plume Displacement Plume O utlet Elbow General Fitting N otes P D
52. o the new pump using the new clip provided 4 W ith the new pump in place on the studs refit the trap discharge pipe ensuring the O ring is in place Reconnect the electrical plug 5 N eatly coil the excess condensate outlet pipe adjacent to the pump ensuring that it is not kinked or restricted 6 Check operation of the pump See Section 10 2 Condensate Pump Level Switches Fig 47a 1 Remove the complete Condensate Pump as described in Section 13 4 and remove the cover 2 Disconnect the wires from the switch es and remove the retaining screws O n the Level Switch remove the circlip and washers connecting the plunger to the actuating arm 3 Fit the new switch es Align the actuating arm of the Level Switch with the plunger ensuring that there is a washer at each side of the arm 4 Reconnect the wires O n the O ver Level Switch there is no connection to the lower spade terminal 5 Check operation of the pump See Section 10 2 43 Control Knob Plastic Button Cover Hinge open PCB Housing Blue CN 11 Jumper Red CN 12 Jumper Fig 49 44 Baxi Heating UK Ltd 2011 PCB Housing Securing Screw 15 0 Changing Components PCB Figs 48 amp 49 WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate system controls before access 1 Pull the control knob off the spindle and remove the plastic button cover Refit them o
53. of vapour from the flue terminal and that it is part of the normal efficient operation of the boiler Baxi Heating UK Ltd 2011 14 0 Servicing the Boiler Annual Servicing WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate system controls before access IMPORTANT W hen servicing ensure that both the gas and electrical supplies including Switched and Permanent Live to the boiler are isolated before any work is started The four LEDs on the facia will all be O FF It is important to isolate the electrical supply at the system isolation switch as it is not possible to do this on the boiler itself Hazardous materials are not used in the construction of this product however reasonable care during service is recommended see Section 1 2 W hen replacing the combustion box door after servicing it is essential that the retaining screws are tightened fully 1 For reasons of safety and economy it is recommended that the boiler is serviced annually Servicing must be performed by a competent person in accordance with BS 7967 4 2 After servicing complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication IMPORTANT During routine servicing and after any maintenance or change of part of the combustion circuit the following must be checked e The integrity of the complete flue system and the flue seals e The integrity of th
54. olate system controls before access IMPORTANT Ensure that both the gas and electrical supplies including Switched and Permanent Live to the boiler are isolated before any work is started The four facia LEDs will be all O FF It is important to isolate the electrical supply at the system isolation switch as it is not possible to do this on the boiler itself Hazardous materials are not used in the construction of this product however reasonable care is recommended see Section 1 2 W hen replacing the combustion box door it is essential that the retaining screws are tightened fully Remove the facia and front door panel For the replacement of some components it will be necessary to drain the boiler Proceed as follows 1 Isolate the water circuit and drain the system as necessary A drain point is located on the heat exchanger manifold at the right hand side of the boiler Fig 45 to enable the heat exchanger to be drained 2 Place a tube on the drain point to drain water away from the electrics Turn anticlockwise to open Fig 45 3 After changing a component recommission the boiler where appropriate and check the inhibitor concentration see Section 6 2 and 10 1 The thermistor safety thermostat interface PCB and the flow switch can be accessed after removal of the pipe access panel Fig 46 Flow Temperature Thermistor and Safety Thermostat Fig 46 1 The procedure is the same for both the th
55. ough 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 pasate lowered onto the flashing maki the collar of the fi amount off the owered onto ei ashing making sure e co ar of the flue Air Duct amp locates securely with the flashing A mastic seal may be Flue D uct necessary From inside the roof adjust the flue to a vertical position and secure to the roof structure with the clamp supplied IMPO RTANT If the boiler is not fitted immediately after the flue system temporary precautions must be taken to prevent rain entry into the room of installation Any precautionary measures must be removed prior to commissioning the boiler Flue Dimensions The standard horizontal flue kit allows for flue lengths between 270mm 105 and 800mm 32 from elbow to terminal Fig 18 Flue Deflector The maximum permissible equivalent flue length is 4 metres a Fig 18a 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 1m e
56. pe to enable complete venting of the boiler The pipe access panel must be removed to do this 2 Additional vents should be fitted at suitable points on the system as required Key to colours b Blue br Brown w White o Orange gr Grey gy Green Yellow 230V 50Hz Y Plan Diverter Cylinder Valve gr l System Control Wiring Centre l Boiler Connection 4 Core Wire Y Plan Room Thermostat System CH Interlocked By Room Thermostat DHW Interlocked By Cylinder Thermostat At least the Radiator s near the Room Thermostat not TRV d Pump run from Switched Live Boiler Connection 4 Core Wire System Control Wiring Centre i S Plan Room Thermostat System CH Interlocked By Room Thermostat DHW Interlocked By Cylinder Thermostat At least the Radiator s near the Room Thermostat not TRV d Pump run from Switched Live Baxi Heating UK Ltd 2011 6 0 System Details LEG System Controls amp W iring This boiler requires a permanent live for Operation of the condensate pump and frost protection 1 To comply with Part L1 of the Building Regulations the heating system into which the boiler is installed should include the following a zone controls b timing controls c boiler control interlocks 2 Such a system needs to b
57. ppliance to manufacturer s instructions Complete the Benchmark Checklist If you notify via the Gas Safe Register the register will issue the Building Regulations certificate on members behalf Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www gassaferegister co uk within 10 days You must ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Gas Safe Register will issue a Building Regulations Compliance Certificate to the property owner and inform the relevant LABC Baxi Heating UK Ltd 2011 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 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 Gas Safe registered company and holding current certificates in the re
58. rder IGALI Heat Exchanger U pper Insulation Pad Fig 60 1 Remove all components in the base of the airbox 2 Remove the burner see section 13 10 3 Remove the heat exchanger see section 13 11 4 Remove the four bolts securing the combustion box base 5 Remove the combustion box base 6 Pull the central insulation panel down from the centre of the heat exchanger 7 Fit the new insulation pad and reassemble in reverse order 16 0 Short Parts List Short Parts List Key GC Description Manufacturers No No Part No A E06 058 Flow Temperature Thermistor Red 240670 B E06 059 Flow Switch 242459 C E06 060 Safety Thermostat Black 242235 D PCB 5129147 E Fan 5109925 F Gas Valve 241900 G E06 085 Viewing W indow 242484 H Condensate Trap 5111714 Electrodes Kit 5132366 J Burner Assy 5107430 K E06 097 Heat Exchanger Assy 242497 L Control Knob 5109996 M Condensate Pump 5117661 N Level Switch 5117591 0 O ver Level Switch 5117592 Un a Gi Dy MN NGG Y R K Baxi Heating UK Ltd 2011 49 Oba os MainsOn Boiler On Lockout LED Light LED Light LED Light Green Green Red x denotes LED flashing Go to Electrical Supply section of the fault finding instructions Live amp N eutral Reversed Incoming Live and N eutral
59. red Condensate Disposal 1 This boiler incorporates an automatic pumped condensate system See the graph opposite for available pump flow rates 2 3 5 metres of flexible 10mm PVC pipe are supplied with the boiler 0 5 metres of this length remains coiled within the boiler to allow removal of the pump assembly This must not be uncoiled to provide extra length 3 A fitting and securing clip Fig B to accept the 10mm PVC pipe and connect to 21 5mm overflow pipe is also supplied 4 The 10mm pipe can be routed to a maximum of 3 metres vertically and then discharge via gravity or be routed horizontally Fig A A combination of vertical and horizontal runs is permissible 5 The pipe must be supported either using suitably spaced clips or run within larger diameter pipe W hen using clips take care not to deform the pipe 6 W hen routing the pipe through a wall it must be suitably sleeved Also the pipe must not be exposed to sources of heat and should be protected in locations where it may be damaged 7 The pipe should be routed so that any sharp bends dips and loops are avoided A minimum radius of 100mm is recommended for any bends N o slope is necessary and air breaks are not required on the pumped part of the condensate run 8 If the boiler is fitted in an unheated location the entire length of condensate pipe should be treated as external and run within insulated larger diameter pipe 17 Termination via in
60. required 3 The flow amp return tails are push fit O ring and clip connections within the boiler case 4 A 20 C drop in temperature across the system is recommended for condensing boilers Existing radiators may be oversized and so allow this but where radiator sizing is marginal it may be advisable to retain a system temperature drop of 11 C 5 In systems using non metallic pipework it is necessary to use copper pipe for the boiler Flow and Return The copper must extend at least 1 metre from the boiler and include any branches Fig 9 6 This boiler does not require a bypass 6 4 Low Head Installation 1 Using a close couple arrangement the minimum head is as shown in the diagrams Figs 10 amp 11 subject to the following conditions a The pump being adjusted to give a 20 C drop across the boiler b The pump must be fitted on the flow c The pump must be fitted in accordance with the pump manufacturer s instructions d The open vent pipe must be taken up from atee ina horizontal section of the flow pipe 2 For heads below 400mm then an alternative utilising a combined vent and feed pipe may be connected Fig 12 This must be a minimum of 22mm diameter It is recommended that an air separator is fitted when using a combined feed and vent pipe Air Vents For correct operation of the flow switch the boiler and system MUST be completely vented 1 A manual air vent is fitted on the flow pi
61. reversed Lights Go to DT YES O to Dry rire section of the fault finding instructions Lights On Off On Odd O 0O YES Go to Ignition Lockout section of the fault finding instructions Go to Overheat Lockout section of the fault finding instructions Go to Fan Lockout section of the fault finding instructions 50 Baxi Heating UK Ltd 2011 17 0 Fault Finding NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after the boiler has been electrically isolated General Fault Finding should only be carried out by someone who is appropriately qualified Lights On On YES Go to Thermistor section of the fault finding l A 7 a instructions Low Electrical Supply Incoming Voltage less than 180V Check System Controls amp System W iring O therwise contact Electricity Provider LV W iring Harness YES Ensure the small 8 way connector is securely plugged into the PCB If the fault persists replace wiring harness Lights On On On Q O O Ow PCB Fault Replace PCB Lights On On QO amp A O O O YES PCB Fault Replace PCB Lights YES PCB Fault Replace PCB Lights YES Go to Condensate Pump section of the fault finding instructions ELECTRICAL SUPPLY No Permanent Live to 240V at A boiler Check Mains Fuse and System W iring YES NO N o Switched Live
62. screws securing the flow switch and return connections and remove the connections Fig 57 4 Remove the screws securing the heat exchanger manifold and remove the manifold Fig 58 5 Ease the combustion box left hand side panel to clear the stud lift the heat exchanger assembly Fig 59 and rotate the bottom upwards whilst pulling it forwards out of the airbox 6 Ensure that the heat exchanger is disengaged from the flue elbow and clear of the stud in the left hand side of the combustion box 7 Fit the new heat exchanger and reassemble in reverse order 8 Recommission the boiler and check the inhibitor concentration see Section 6 2 and 10 1 47 i C LDS IRINTE Central Insulation Panel U pper Insulation Pad Pad eisein Burner Combustion Box Base Support Bracket Combustion Box Base Securing Screws Burner Securing Screws 48 Baxi Heating UK Ltd 2011 15 0 Changing Components IGAKS Heat Exchanger Lower Insulation Pad Fig 60 1 Remove all components in the base of the airbox 2 Remove the burner see section 13 10 3 Remove the four bolts securing the combustion box base 4 Remove the combustion box base 5 Pull the central insulation panel down from the centre of the heat exchanger and remove the lower insulation pad 6 Fit the new insulation pad and reassemble in reverse o
63. shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths O K W here both lengths have been determined they can be applied to the graph to check that the installation is permissible For example if it was known that 2 metres of concentric flue and 4 metres of 70 exhaust were required the values could be applied to the graph as shown in Example 2 As the point of intersection of the dotted lines is below the solid diagonal line the combination of lengths is shown to be acceptable Example 3 Flue Lengths O K In the example shown assume that the concentric part of the flue needs to be 2 metres long Find the position of 2 on the horizontal axis of the graph and then project upwards to the solid diagonal line This is represented by the vertical thick dotted line W here this dotted line intersects with the solid diagonal line on the graph project across to the vertical axis As can be seen this corresponds with 14 metres Therefore the total equivalent length of the 70 exhaust can be up to 14 metres Any elbow equivalencies must be accounted for i e 93 elbows are equal to 1 metre each 45 elbow to 0 5 metres Flue Length W orked Example In Fig D opposite an additional 93 elbow and pair of 45 elbows have been included in the 70 exhaust Also 3 straight extension pieces have been used To calculate total length Length of 7
64. sioned by print name Gas Safe Register Number Company Name Telephone Number Company Address Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather ie Optimum Start Programmer Timer E Room Thermostat Compensation Control Time and Temperature Control to Hot Water linder Thermostat and Programmer Timer Combination Boiler E Heating Zone Valves Fitted E Not Required Hot Water Zone Valves Fitted B Not Required Thermostatic Radiator Valves Fitted E Not Required E Automatic Bypass to System i NotRequirea _ Boiler Interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litres CENTRAL HEATING MODE Measure and Record Gas Rate Burner Operating Pressure if applicable Central Heating Return Temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas Rate Burner Operating Pressure at maximum rate Cold Water
65. spare part when replacing controls Service 1 Date Engineer Name Service 2 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 3 Date Engineer Name Service 4 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 5 Date Engineer Name Service 6 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Operative ID No Comments Comments Signature Signature Service 7 Date Engineer Name Service 8 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 9 Date Engineer Name Service 10 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature
66. t least 2 metres above ground level It must be secured as shown in Fig C The outlet must be positioned so that any condensate plume is directed away from adjacent surfaces ng 4 It is possible to reduce or increase with the addition of extensions the length of either or both the 70 110 concentric and 70 exhaust 5 Standard concentric flue extension kits may be added gt Outlet must be Peak MUST be between the boiler elbow and the terminal assembly 45 at least 45 from 5 U ppermost T wall face p 6 The minimum length of the concentric flue is 100mm when measured from the edge of the boiler flue elbow There is a further 45mm engagement into the elbow IMPORTANT The maximum equivalent length of y concentric flue is 4 metres NJ Additional elbows may be fitted in the concentric flue but the equivalent length must be reduced by 1 metre 93 elbow or 0 5 metres 45 elbow 7 70 1 metre extensions including support bracket and additional 93 amp 45 elbows are available Any additional 93 500mm Min amp 45 elbows must be accounted for when calculating flue lengths 70 93 elbows are equivalent to 3 5 metres of straight length and 45 elbows to 1 metre Fig A NOTE Permitted positions of the plume outlet relative to doors windows etc are the same as for conventional 2 L concentric flues as detailed in the main Installation amp O utlet Connectio
67. tc Terminal Guard Fig 19 1 W hen codes of practice dictate the use of terminal guards they can be obtained from most Plumbers and Builders Merchants 2 W hen ordering a terminal guard quote the appliance model number 3 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated 89 Flue Deflector Fig 18a 1 If required push the flue deflector over the terminal end and rotate to the optimum angle for deflecting plume Secure the deflector to the terminal with screws provided 24 Baxi Heating UK Ltd 2011 9 0 Plume Displacement Plume Displacement Kit P D K Kit No 5121371 Content of kit 1 70 110 Concentric Flue 1m 70 Dia Exhaust Flue Pipe QOQ Plume O utlet Peak MUST be Uppermost 1 3 0 94 metre 2 Support Brackets 1 93 Elbow Plume O utlet Assembly 1 Flue Trim EN 2 0 Rings 1 Elbow with Gasket 1 This kit is recommended for installations where the condensate plume emitted from the flue may cause a nuisance or affect the surroundings 2 The terminal must be positioned outside the building with the outlet connection upwards 3 The 70 pipe connects to the outlet of the concentric A terminal assembly The elbow plume outlet must be fitted to the end of the 70 pipe O NOTE The plume outlet must always be at least 45 to the wall with the peak uppermost to prevent rain entry P Figs A amp B and be a
68. ternal discharge branch e g sink waste downstream Direct Connect Fitting Pipe must terminate above water level but below surrounding surface Branch of Tee to be 10 from vertical A From Boiler 10 ae I i i Fig C i I Termination to a drain or gully Pipe must terminate above Water level but below surrounding surface From Boiler Termination to a purpose made soak away 500mm Min From Boiler Holes in the soak away must seereis face away from the building Va Fig F 18 Baxi Heating UK Ltd 2011 7 0 Site Requirement Condensate Disposal cont 9 Ensure that the condensate can discharge freely without blockage or restriction of the pipe into the drain 10 Examples are shown of condensate pipe methods of termination i via an internal discharge branch e g sink waste Fig C ii to an internal or external soil and vent pipe Fig D iii to adrain or gully Fig E Ensure that the condensate can discharge freely without blockage or restriction of the pipe into the drain iv to a soakaway Fig F ee l 7 0 Site Requirements Terminal Position with Minimum Distance Fig 17 A Directly below an opening air brick opening windows etc 300 Flue Ba Above an opening air brick opening window etc 300 C Horizontally to an opening air brick opening window etc 300 NOTE Due to the high
69. to boiler Check System 2 sah at B Controls and System W iring YES Check P L wiring from terminal block to PCB YES 240V a D Check S L wiring from i terminal block to PCB YES Check for short circuit on condensate pump fan amp gas valve Replace if shorted amp replace fuse PCB fuse OK Replace PCB Baxi Heating UK Ltd 2011 17 0 Fault Finding SEISIS Fuse B z 3 B E 51 DRY FIRE Is the NO ii r system full of water fe wit water an bleed out all air YES Is the NO a Pump or Pump W iring pump running fault YES Unplug YES 5 way PCB connector Is Replace PCB there continuity between H H Viewed from W ire Entry end NO Disconnect YES Flow Switch Inline F sini connector W ith pump running is W ires from inline there continuity across flow connector to PCB faulty switch NO Remove NO Is there a blockage in the system flow switch from boiler Is there a physical blockage to the paddle within the flow switch NO Replace Flow Switch YES YES Remove Blockage Remove Blockage 52 Baxi Heating UK Ltd 2011 17 0 Fault Finding IGNITION LOCKOUT Is there gas at gas valve inlet NO Check isolation valve and gas supply YES Reset Lockout NO Is there gas flow check at meter YES Is there at least 18mbar dynamic at gas valve inlet
70. to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IG E U P 7 Gas Installations in Timber Framed H ousing Compartment 1 W here the boiler is installed in a cupboard or compartment no air vents are required for cooling purposes providing that the minimum dimensions below are maintained W idth 400mm Height 875mm Depth 525mm 2 Any compartment should be large enough to house the boiler only 15 5mm Min 5mm Min 7 0 Site Requirements lt 390mm gt Clearances Figs 15 amp 16 15mm Min ee 25mm if under 1 These dimensions include the necessary clearances nonremovable around the boiler for case removal spanner access and air worktop 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 For side flue installations also See Section 8 1 Figs 20 amp 21 see A 2 It is recommended that any worktop is removable for servicing access ee Gas Supply 1 Check that the information concerning the state of adjustment given on the data plate is compatible with local supply conditions 2 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
71. uns is permissible 5 The pipe must be supported either using suitably spaced clips or run within larger diameter pipe W hen using clips take care not to deform the pipe 6 W hen routing the pipe through a wall it must be suitably sleeved Also the pipe must not be exposed to sources of heat and should be protected in locations where it may be damaged 7 The pipe should be routed so that any sharp bends dips and loops are avoided A minimum radius of 100mm is recommended for any bends No slope is necessary and air breaks are not required on the pumped part of the condensate run 8 If the boiler is fitted in an unheated location the entire length of condensate pipe should be treated as external and run within insulated larger diameter pipe 9 Ensure that the condensate can discharge freely without blockage or restriction of the pipe into the drain 10 Examples are shown of condensate pipe methods of termination i Via an internal discharge branch e g sink waste Fig B to an internal or external soil and vent pipe Fig C to a drain or gully Fig D Ensure that the condensate can discharge freely without blockage or restriction of the pipe into the drain iv to a soakaway Fig E ii ili Fig 32 Fig 33 W iring from System Controls S L Switched Live Earth N Neutral P L Permanent Live Baxi Heating UK Ltd 2011
72. uring Clip 8 5mm OD tai 21 5mm O D to fit O verflow Pipe Termination via internal discharge branch e g sink waste downstream Direct Connect Fitting From Boiler l Fig C Termination to a drain or gully From Boiler 32 Baxi Heating UK Ltd 2011 Pipe must terminate above water level but below surrounding surface Branch of Tee to be 10 from vertical 1 1 1 1 1 1 1 1 l Pipe must terminate above water level but below surrounding surface Termination to a purpose made soak away 500mm Min From Boiler Holes in the soak away must face away from the building Fig F 7a 10 0 Installation Making the C ondensate D rain Connection 1 3 5 metres of flexible 10mm PVC pipe are supplied with the boiler ready connected to the pump 0 5 metres of this length remains coiled within the boiler to allow removal of the pump assembly This must not be uncoiled to provide extra length 2 A fitting and securing clip Fig B to accept the 10mm PVC pipe and connect to 21 5mm overflow pipe is also supplied W hen using this fitting to connect to a 21 5mm overflow tee piece the branch must be vertical 10 Fig C 3 Feed the pipe through the grommet in the rear panel and connect to the drain system 4 The 10mm pipe can be routed to a maximum of 3 metres vertically and then discharge via gravity or be routed horizontally Fig A A combination of vertical and horizontal r
73. ving the four screws 2 If required remove the condensate pump to increase access 4 see Section 13 4 and undo the case pressure pipe from the O Qa Boiler Side 12 gt valve 3 Disconnect the electrical plug from the gas valve Aluminium Spacer 4 Remove the fan see Section 13 6 and injector pipe 5 Remove the two gas valve securing screws from inside the air box holding the gas valve and remove the valve 6 Remove the aluminium spacer and its gasket from the gas valve Fig 53 7 Fit the aluminium spacer and its gasket to the new valve 8 Fit the new gas valve and reassemble in reverse order NOTE Check for gas tightness after replacing gas valve 9 Check the CO level If the level is greater than that quoted telephone the Technical Enquiries for further advice Securing Nut stom Condensate Trap Fig 54 1 Disconnect the condensate trap from the base of the heat exchanger 2 Disconnect the condensate drain O ring connection from the condensate trap and condensate pump For ease of access also remove the pump Condensate Trap 0 3 Undo the condensate trap lock nut 4 Remove the condensate trap from the boiler Lock Nut 5 Disconnect the sensor leads 6 Fit the new condensate trap and reassemble in reverse order W hen refitting the pipe from the trap to the pump ensure that all seals and connections are
74. we recommend the use of the plume WYN Property Boundary Line displacement kit e 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 150mm from RIK ie any opening windows or doors Ww Plume Displacement Kit sl 2 tid Likely flue positions requiring Fig 17 a flue terminal guard 9 O pening W indow or Door Baxi Heating UK Ltd 2011 Fig 17a MIN 19 Horizontal Flue System Examples Plume Displacement 70 110 dia Kit 1M Extensions 45 amp 93 bends are also available see Section 9 0 N OTE Horizontal flue pipes should always be installed with a 1 5 fall from the terminal to allow condensate to run back to the boiler This bend is equivalent to 0 5 metre NA DMA gt This bend is equivalent to 0 5 metre Total equivalent length A B 2x45 Bends 20 Baxi Heating UK Ltd 2011 8 0 Flue Options Horizontal Flue Systems Only a flue approved with the Potterton Gold FSB HE 30 can be used Concentric The maximum equivalent lengths are 4m hori
75. y upward connection with no intervening valve or restrictions and should be positioned to facilitate testing The valve should be pre set and non adjustable to operate at a pressure of 3 bar 45 Ibf in It must be arranged to discharge any water or steam through a pipe to a safe outlet position 2 PRESSURE GAUGE A pressure gauge of minimum range 0 4 bar 0 60 Ibf in with a fill pressure indicator must be fitted to the system preferably at the same point as the expansion vessel in an easily visible position 3 EXPAN SION VESSEL An expansion vessel complying with the requirements of BS 4814 must be fitted to the system by means of a connection close to the inlet side of the circulating pump in accordance with the manufacturers instructions the connecting pipe being unrestricted and not less than 15mm 2 in nominal size The volume of the vessel should be suitable for the system water content and the nitrogen or air charge pressure should not be less than the system static head See Table 1 Further details of sealed system design can be obtained from BS 5449 and the British Gas publication entitled Specifications for Domestic W et Central H eating Systems 4 FILLING POINT A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement refilling The sealed primary circuits may be filled or replenished
76. zontal or vertical Their lengths exclude the standard elbow and flue terminal assembly horizontal and terminal assembly vertical Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 45 bend 0 5m 93 bend 10m NOTE Flue length is measured from point i to ii as shown IMPORTANT All flue systems must be securely supported at least once every metre Suitable pipe supports are available as accessories Vertical Flue Vertical Flue System Examples Twin Pipe Ca System Examples Total Equivalent Length A B C 1x90 Bend Roof Terminal All vertical and angled runs must be included measured from the boiler joint with the flue terminal point Y O ne 91 5 bend or two 135 bends can be included without reduction of the flue length If further elbows are required the flue length must be reduced by the following amounts 1 metre for each 91 5 bend i 0 5 metre for each 135 bend J adaptor point X to the lt x 8 o i bend is equivalent to 1 metre Baxi Heating UK Ltd 2011 8 0 Flue Options Twin amp Vertical Flue Systems Concentric The maximum equivalent lengths are 4m vertical Their lengths exclude the standard elbow and terminal assembly vertical Twin Flue The total maximum equivalent flue length

Baxi Potterton Gold FSB 30 HE Boiler User Manual

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