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© Baxi Heating UK Ltd 2007

Installation & Service Instructions Promax SystemHE PlusRange

These instructions include the Benchmark Commissioning Checklistand should be left with the user for safe keeping.

2 © Baxi Heating UK Ltd 2007

Natural Gas

Potterton Promax System 12 HE PlusG.C.No 41 591 90Potterton Promax System 15 HE PlusG.C.No 41 591 91Potterton Promax System 18 HE PlusG.C.No 41 591 92Potterton Promax System 24 HE PlusG.C.No 41 601 21Potterton Promax System 32 HE PlusG.C.No 41 591 93

Building Regulations and the Benchmark CommissioningChecklist

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

CORGI operate a Self Certification Scheme for gas heatingappliances.

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

With the introduction of Self Certification Schemes, theBenchmark Logbook is being withdrawn. However, a similardocument in the form of a commissioning checklist and serviceinterval record is incorporated at the back of these instructions.

This company is a member of the Benchmark initiative and fullysupports the aims of the programme. Its aim is to improve thestandards of installation and commissioning of central heatingsystems in the UK and to encourage the regular servicing of allcentral heating systems to ensure safety and efficiency.

Building Regulations require that installations should complywith manufacturer's instructions. It is therefore important thatthe commissioning checklist is completed by the installer. Therelevant section of Building Regulations only relates todwellings. Therefore the checklist only applies if the appliance isbeing installed in a dwelling or some related structure.

The flowchart opposite gives guidance for installers on theprocess necessary to ensure compliance with BuildingRegulations.

Baxi Heating UK Ltd is a BS-EN ISO 9001 Accredited Company

The code of practice for the installation,commissioning & servicing of central

heating systems.

“Potterton” supports

© Baxi Heating UK Ltd 2007 All rights reserved. No part of this publication maybe reproduced or transmitted in any form or by any means, or stored in anyretrieval system of any nature (including in any database), in each case whetherelectronic, mechanical, recording or otherwise, without the prior writtenpermission of the copyright owner, except for permitted fair dealing underCopyrights, Designs and Patents Act 1988.

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

The Company Secretary, Baxi Heating UK Ltd, Pentagon House, Sir Frank Whittle Road, Derby, DE21 4XA.

Full acknowledgement of author and source must be given.

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

�

This product has an energy rating (A) on a scale of A to G.For more information see www.boilers.org.uk. This is a certification mark.

3

Installer Notification Guidelines


Choose BuildingRegulations Notification

Route

Contact your relevant LocalAuthority Building Control(LABC) who will arrangean inspection or contacta government approved

inspector

LABC will record the dataand will issue a

certificate of compliance

CORGI will record the data andwill send a certificate of

compliance to the property

You must ensure that thenotification number issued by

CORGI is written onto theBenchmark Checklist

Scheme Members only

Call CORGI on: 0870 88 88 777or log onto:

www.corgi-notify.comwithin 10 days

If you notify via CORGI Scheme,CORGI will then notify the

relevant Local AuthorityBuilding Control Scheme

on member's behalf

Complete theBenchmark Checklist

Install and Commission thisappliance to manufacturer's

instructions

Competent Person'sSelf Certification Scheme

Building Control

Complete theBenchmark Checklist

Install and Commission thisappliance to manufacturer's

instructions

4

Legislation


Codes of Practice - refer to the most recent version

IMPORTANT - Installation, Commissioning, Service & Repair

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

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

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

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

The addition of anything that may interfere with the normal operation of the appliancewithout express written permission from the manufacturer or his agent could invalidatethe appliance warranty. In GB this could also infringe the Gas Safety (Installation andUse) Regulations.

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

All CORGI registered installers carry a CORGI identification card and have aregistration number. You can check your installer is registered by telephoning 08704012300 or writing to:-

1 Elmwood,Chineham Business Park,

Crockford Lane,Basingstoke. RG24 8WG

or check online at www.corgi-gas-safety.com

This company declare that no substances harmful to healthare contained in the appliance or used during appliancemanufacture.

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

In GB, the installation must be carried out by a CORGIRegistered Installer. It must be carried out in accordance withthe relevant requirements of the:• Gas Safety (Installation & Use) Regulations.• The appropriate Building Regulations either The Building

Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland).

• The Water Fittings Regulations or Water Byelaws in Scotland.

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

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

In IE, the installation must be carried out by a competentPerson and installed in accordance with the current edition ofI.S. 813 ‘Domestic Gas Installations’, the current BuildingRegulations and reference should be made to the current ETCIrules for electrical installation.

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

In GB the following Codes of Practice apply:Standard ScopeBS 6891 Gas Installation.BS 5546 Installation of hot water supplies for domestic

purposes.BS 5449 Forced circulation hot water systems.BS 6798 Installation of gas fired hot water boilers.BS 5440 Part 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 ScopeI.S. 813 Domestic Gas Installations.The following standards give valuable additional information;BS 5546 Installation of hot water supplies for domestic

purposes.BS 5449 Forced circulation hot water systems.BS 7074 Expansion vessels and ancillary equipment for

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

central heating systems.

The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)Regulations 1993 No 3083” and is deemed to meet the requirements of Directive92/42/EEC on the energy efficiency requirements for new hot water boilers fired withliquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by: Notified Body 0085.

Product/Production certified by:Notified Body 0085.

For GB/IE only.

5

Safe Manual Handling


General

The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.

Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands.Health & Safety is the responsibility of EVERYONE.

There is no ‘safe’ limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.

Do not handle or lift unless you feel physically able.

Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.

Preparation

Co-ordinate movements - know where, and when, you are both going.

Minimise the number of times needed to move the boiler - plan ahead.

Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special careon ladders/into lofts.

Technique

When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards andsideways and keep the load as close to your body as possible.

Where possible transport the boiler using a sack truck or other suitable trolley.

Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the‘Installation’ section of these instructions for recommended lift points.

Remember

The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.

If at any time when installing the boiler you feel that you may have injured yourself STOP !! DO NOT ‘work through’ the pain - you may cause further injury.

IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!


CONTENTS

1.0 Introduction 7

2.0 General Layout 8

3.0 Appliance Operation 9

4.0 Technical Data 10

5.0 Dimensions and Fixings 11

6.0 System Details 12

7.0 Site Requirements 14

8.0 Flue Options 18

9.0 Plume Displacement 23

10.0 Installation 27

11.0 Commissioning 32

12.0 Completion 34

13.0 Servicing 35

14.0 Changing Components 37

15.0 Combustion Check 45

16.0 Electrical 46

17.0 Short Parts List 47

18.0 Fault Finding 48

Benchmark Checklist 54

Section Page

7

1.0 Introduction


1.1 Description

1. The Potterton Promax System HE Plus is a fully automaticgas fired wall mounted condensing system boiler. It is roomsealed and fan assisted.

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

12 models - 12 kW 13 kW (Condensing)

15 models - 15 kW 16.2 kW (Condensing)




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

4. The boiler incorporates a circulating pump and expansionvessel. It is suitable for use only on fully pumped sealedsystems.

5. The boiler data badge gives details of the model, serialnumber and Gas Council number and is situated on the innerdoor panel. It is visible when the case front panel is removed(Fig. 1).

6. The boiler model name and serial number are also shownon the information label on the rear of the lower door panel.This is for user reference.

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

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

9. All systems must be thoroughly flushed and treated withinhibitor (see section 6.2).

1.2 Contents of Pack

The pack contains:-• Boiler• Wall Plate (including taps)• Set of Pipe Connections• Template • Literature Pack

Fig. 1

Control Box

Case Front Panel

Data Badge

Information Label

8

2.0 General Layout


2.1 Layout

1. Expansion Vessel

2. Automatic Air Vent

3. Circulation Pump

4. Drain Off Point

5. Pressure Relief Valve

6. Selector Switch

7. Central Heating System Pressure Gauge

8. PCB

9. Control Box

10. Gas Valve

11. Condensate Trap

12. Flame Sensing Electrode

13. Spark Electrode

14. Primary Heat Exchanger

15. Fan Assembly

16. On/Off/Reset Selector Switch

17. Central Heating Temperature Control

18. Calibration Control

19. Venturi

20. Air/Gas Collector

21. Combustion Box Cover & Burner

22. Igniter

23. Burner On Light

24. Central Heating Mode Light

25. Display

1

16 17 18 7

Reset

bar

0

1

2

3

4

21

2

34

5

6

78

9

10

11

12

13

14

15

19

20

22

23

24

25

9

3.0 Appliance Operation


3.1 Operating Mode (Fig. 2)

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

2. When the flow temperature exceeds the settingtemperature, a 3 minute delay occurs before the burnerrelights automatically (anti-cycling). The pump continues torun during this period.

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

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

3.2 Frost Protection Mode

1. The frost protection mode is integral to the appliance andfunctions when the selector switch (see Section 2.1) is in theON position ( ). If the system temperature falls below5° C then the boiler will fire on its minimum setting until aflow temperature of 30° C is reached. Further protectioncan be incorporated by using a system frost thermostat.

3.3 Pump Protection

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

1

2

4

5

6

7

8

19

18

9

10 12 11

14

13

15

16

17

3

Key

1 Heat Exchanger2 Burner 3 Ignition Electrode4 Flame Sensing Electrode5 Gas Valve6 Pump7 Automatic Air Vent8 Pressure Relief Valve9 Boiler Drain Point10 Gas Inlet11 Boiler Flow12 Boiler Return13 Pressure Gauge14 Automatic By-Pass15 Water Pressure Sensor16 Safety Thermostat17 Temperature Sensor18 Expansion Vessel19 Return Temperature Sensor20 Fan

Boiler Primary Circuit

Fig. 2

20


This value is used in the UK Government’s Standard Assessment Procedure

(SAP) for energy rating of dwellings. The test data from which it has been

calculated have been certified by 0085.

SEDBUK Declaration For Promax System HE Plus

The seasonal efficiency (SEDBUK) is:-

90.2% (15, 18 & 24) 90.1% (12 & 32) Band A

4.0 Technical Data

4.1 Promax System 12,15,18, 24, & 32 HE

Flue Terminal Diameter 100mmDimensions Projection 125mm

Outercase DimensionsCasing Height - 780mmOverall Height Inc Flue Elbow - 965mmCasing Width - 450mmCasing Depth - 345mm

Central Heating Primary CircuitPressures

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

PumpAvailable Head See graph below

Expansion Vessel - (Integral with appliance)bar

Min Pre-charge Pressure 0.5

litreMax Capacity of CH System 125

Primary Water Contentof Boiler (unpressurised) 2.5Connections copper tails

Gas Supply - 22mmCentral Heating Flow - 22mmCentral Heating Return - 22mmPressure Relief Discharge - 15mm

TemperaturesFlow Temp (adjustable)

25°C to 80°C max (± 5°C)

NOx Class 5

0200 400 600 800 1000 1200

0.5

1

1.5

2

2.5

3

3.5

4

Met

re (

wg)

Flow Rate (l/h)

Pump - Available Head

0

5

5.5

4.5

ClearancesAbove Casing 200 mm MinBelow Casing 200 mm MinFront 450 mm Min (For Servicing)

Front 5 mm Min (In Operation)

L.H. Side 5 mm MinR.H. Side 5 mm Min (In Operation)

Heat Input (Net) Max Min

12 model kW 12.4 4

15 model kW 15.4 3.9

18 model kW 18.5 4.3

24 model kW 24.7 7

32 model kW 32.8 9.7

Heat Output (Non-Condensing)Max Min

12 model kW 12 3.9

15 model kW 15 3.9

18 model kW 18 4.2

24 model kW 24 6.8

32 model kW 32 9.4

Electrical Supply 230V~ 50Hz (Appliance must be connected to an

earthed supply)

Power Consumption 12 model 145W15 model 130W18 model 140W24 model 150W32 model 160W

Electrical Protection IPX5D

Internal Fuse Rating F2L

Appliance Category CAT I 2H

Inlet Pressure (Natural Gas - G20)mbar 20

Injector (Natural Gas - G20)

12 model 4mm

15 model 4.5mm

18 model 5.7mm

24 model 7.5mm

32 model 12mm

Appliance Type C13 C33 C53

Heat Output (Condensing)Max Min

12 model kW 13 4.2

15 model kW 16.2 4.2

18 model kW 19.4 4.5

24 model kW 25.9 7.4

32 model kW 34.4 10.2

Max Gas Rate (Natural Gas - G20)(After 10 mins)

12 model m3/h 1.31

15 model m3/h 1.69

18 model m3/h 1.95

24 model m3/h 2.61

32 model m3/h 3.48

Condensate DrainTo accept 21.5mm (3/4 in) plastic waste pipe

Heat Input (Gross) Max Min

12 model kW 13.8 4.4

15 model kW 17.1 4

18 model kW 20.5 4.5

24 model kW 27.4 7.8

32 model kW 36.4 10.8

External Fuse Rating 3A

Weights12, 15 &18 24

Packaged Boiler Carton 52.5kg 53.5kgInstallation Lift Weight 43kg 44kg

32Packaged Boiler Carton 54.5kgInstallation Lift Weight 45kg

11

5.0 Dimensions and Fixings


360° Orientation

Tube Ø 100mm

DC

B

A

EG

F

1.5° to 3o

H

HeatingReturn(22mm)

HeatingFlow

(22mm)

Pressure ReliefValve

(15mm)

GasInlet

(22mm)

130 mm 130 mm 65 mm

CondensateDrain

32.5 mm

Tap Rail

Dimensions

A 780mm

B 345mm

C 450mm

D 116mm Ø Min.

E 185mm(207mm for 80/125mm flue systems)

F 145mm

G 131mm

H 180mm

12

6.0 System Details


6.1 Central Heating Circuit

1. The appliance is suitable for fully pumped SEALED SYSTEMSONLY.

Treatment of Water Circulating Systems• All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system willdeteriorate as corrosion sludge accumulates within the system,risking damage to pump and valves, boiler noise and circulationproblems.

• When fitting new systems flux will be evident within the system,which can lead to damage of system components.

• All systems must be thoroughly drained and flushed out. Using,for example Betz-Dearborn Sentinel X300 or X400 or FernoxSuperfloc Universal Cleanser. They should be used following theflushing agent manufacturer’s instructions.

• System additives - corrosion inhibitors and flushing agents/descalers should comply to BS7593 requirements, e.g.Betz-Dearborn Sentinel X100 and Fernox-Copal which should beused following the inhibitor manufacturer’s instructions.

Failure to flush and add inhibitor to the system willinvalidate the appliance warranty.

• It is important to check the inhibitor concentration afterinstallation, system modification and at every service inaccordance with the manufacturer’s instructions. (Test kits areavailable from inhibitor stockists.)

• For information or advice regarding any of the above contactTechnical Enquiries.

6.2 Bypass

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

6.3 System Control

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

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

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

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

13

6.0 System Details


6.4 System Filling and Pressurising

1. A filling point connection on the central heating returnpipework must be provided to facilitate initial filling andpressurising and also any subsequent water lossreplacement/refilling.

2. The filling method adopted must be in accordance with allrelevant water supply regulations and use approvedequipment.

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

4. The sealed primary circuits may be filled or replenished bymeans of a temporary connection between the circuit and asupply pipe, provided a ‘Listed’ double check valve or someother no less effective backflow prevention device ispermanently connected at the inlet to the circuit and thetemporary connection is removed after use.

6.5 Expansion Vessel

1. The appliance expansion vessel is pre-charged to 0.5 bar.Therefore, the minimum cold fill pressure is 0.5 bar. Thevessel is suitable for correct operation for system capacities upto 125 litres. For greater system capacities an additionalexpansion vessel must be fitted. For GB refer to BS 7074 Pt 1.For IE, the current edition of I.S. 813 “Domestic GasInstallations”.

6.6 Pressure Relief Valve (Fig. 4)

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

2. The pressure relief discharge pipe should be not less than15mm dia, run continuously downward, and discharge outsidethe building, preferably over a drain. It should be routed insuch a manner that no hazard occurs to occupants or causesdamage to wiring or electrical components. The end of thepipe should terminate facing down and towards the wall.

3. The discharge must not be above a window, entrance orother public access. Consideration must be given to thepossibility that boiling water/steam could discharge from thepipe.

Fig. 3

Fig. 4

StopValve

DoubleCheckValve

DHWMainsInlet

CHReturn

TemporaryHose

Pressure Relief ValveDischarge Pipe

StopValve

14

7.0 Site Requirements


7.1 Location

1. The boiler may be fitted to any suitable wall with the fluepassing through an outside wall or roof and discharging toatmosphere in a position permitting satisfactory removal ofcombustion products and providing an adequate air supply.The boiler should be fitted within the building unlessotherwise protected by a suitable enclosure i.e. garage orouthouse. (The boiler may be fitted inside a cupboard-seeSection 7.3).

2. If the boiler is sited in an unheated enclosure then it isrecommended to leave the ON/OFF Selector Switch in theOn position.

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

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

7.2 Clearances (Figs. 5 & 6)

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

2. These dimensions include the necessary clearances aroundthe boiler for case removal, spanner access and airmovement. Additional clearances may be required for thepassage of pipes around local obstructions such as joistsrunning parallel to the front face of the boiler.

200mm Min

780mm

450mm

200mm Min (300mm Min if

using 80/125mmflueing system)

5mm Min

5mm Min

450mm Min

For ServicingPurposes

Fig. 5

Fig. 6In Operation

5mm Min

1.5° to 3°

15



7.3 Ventilation of Compartments

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

2. BS 5440: Part 2 refers to room sealed appliancesinstalled in compartments. The appliance will run sufficientlycool without ventilation.

7.4 Gas Supply

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

2. The connection to the appliance is a 22mm copper taillocated at the rear of the gas service cock (Fig. 7).

3. Ensure that the pipework from the meter to theappliance is of adequate size, and the demands of anyother gas appliances in the property are taken intoconsideration. Do not use pipes of a smaller diameter thanthe boiler gas connection (22mm).

7.5 Electrical Supply

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

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

NOTE: The method of connection to the electricitysupply must facilitate complete electrical isolation ofthe appliance.

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

3. When the system includes an indirect domestic hotwater cylinder it is recommended that a cylinderthermostat is used in conjunction with a 3 port 2 positionvalve or 2 port zone valve.

7.6 Bath & Shower Rooms

1. If the boiler is fitted in a room containing a bath orshower and NOT FITTED with any optional integral timeror thermostat, it can be fitted in zone 2, (Figs. A & B showszone dimensions for a bathtub. For other examples refer toSection 601 of the Current I.E.E. Wiring Regulations)reference must be made to the relevant requirements.In GB this is the current I.E.E. Wiring Regulations andBuilding Regulations.In IE reference should be made to the current edition of I.S.813 “Domestic Gas Installations” and the current ETCIrules.

Fig. 7

Gas Service Cock

Zone 2

Zone 1

Zone 0

Zone 2Zone 3

Zone 3

Zone 2

WindowRecess

WindowRecess

0.6 m 2.4 m

Ceiling

OutsideZones

Outside Zones

Zone 3

Zone 3

Zone 2

Zone 2Zone 1

Zone 0

2.25 m

Zone 2

WindowRecess

3.0 m

2.4 m0.6 m

Fig. A

Fig. B

In GB Only

In GB Only

16



7.7 Condensate Drain

FAILURE TO INSTALL THE CONDENSATE DISCHARGEPIPEWORK CORRECTLY WILL AFFECT THE RELIABLEOPERATION OF THE BOILER

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

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

2. Ensure the discharge of condensate complies with anynational or local regulations in force. BS 6798:2000 & Part H1 of the Building Regulations givefurther guidance.

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

4. Metal pipework is NOT suitable for use in condensatedischarge systems.

5. The pipe should be a minimum of 21.5mm diameter andmust be supported using suitably spaced clips to preventsagging.

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

7. External runs greater than 3 metres or runs in cold areasshould use 32mm waste pipe.

8. If the boiler is fitted in an unheated location the entirecondensate discharge pipe should be treated as an externalrun.

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

10. When discharging condensate into a soil stack or wastepipe the effects of existing plumbing must be considered. If soilpipes or waste pipes are subjected to internal pressurefluctuations when WC's are flushed or sinks emptied thenback-pressure may force water out of the boiler trap andcause appliance lockout.

Examples are shown of the following methods of termination:-i) to an internal soil & vent pipeii) via an internal discharge branch (e.g. sink waste)iii) to a drain or gullyiv) to a purpose made soakaway

Boiler

2.5° Minimum fall

Termination to an internal soil andvent pipe

450mm min

Boiler

2.5° Minimum fall

External termination via internal dischargebranch

e.g sink waste - downstream

SinkPipe must terminateabove water level butbelow surroundingsurface

BoilerPipe must terminate abovewater level but belowsurrounding surface

2.5° Minimum fall

Termination to a drain or gully

Boiler

500mm min

2.5° Minimum fall

Termination to a purpose made soak-away

Holes in the soak-away mustface away from the building

50mm per metre of pipe run




17



7.8 Flue

NOTE: Due to the nature of the boiler a plume of watervapour will be discharged from the flue. This should betaken into account when siting the flue terminal.

1. The following guidelines indicate the general requirementsfor siting balanced flue terminals. For GB recommendationsare given in BS 5440 Pt 1. For IE recommendations are givenin the current edition of I.S. 813 “Domestic GasInstallations”.

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

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

IMPORTANT:• Only ONE 25mm clearance is allowed per installation.• Under car ports we recommend the use of the plume

displacement kit.• The terminal position must ensure the safe and

nuisance - free dispersal of combustion products.

N

I

I

G

F

M

I

AA

F

H

J,K

DE

H

Likely flue positions requiring a flue terminal guard

C

RA

I

J,K

I

L

S

B

T

U

Fig. 9

Fig. 8

300 minTerminalAssembly

Top View Rear Flue

Property Boundary Line

NOTE: The distance from a fanned draught appliance terminalinstalled parallel to a boundary may not be less than 300mm inaccordance with the diagram below

Terminal Position with Minimum Distance (Fig. 9) (mm)

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

Ba Above an opening, air brick, opening window etc. 300Ca Horizontally to an opening, air brick, opening window etc. 300D Below gutters, soil pipes or drain pipes. 25E Below eaves. 25F Below balconies or car port roof. 25G From a vertical drain pipe or soil pipe. 25H From an internal or external corner. 25I Above ground, roof or balcony level. 300J From a surface or boundary line facing a terminal. 600K From a terminal facing a terminal (Horizontal flue). 1200

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

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

a In addition, the terminal should be no nearer than 150 mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame. See BS 5440 Pt. 1.

*

Opening Windowor Door

100mmMIN.

IMPORTANT: If fitting a PlumeDisplacement Flue Kit, the air inletmust be a minimum of 100mm fromany opening windows or doors (seeSection 8.0).

PlumeDisplacement Kit

Air Inlet

Fig. 10

18

8.0 Flue Options


HorizontalFlues

Y

X

Plume Displacement 60 /100 dia Kit1M Extensions 45° & 93° bends arealso available - see Section 9.0Plume Displacement.

8.1 Horizontal Flue Systems

1. The standard flue is suitable only for horizontaltermination applications.

2. Maximum permissible equivalent flue lengths are:-

60/100 80/125Horizontal Concentric 10 metres 20 metres

3. Any additional “in line” bends in the flue system must betaken into consideration. Their equivalent lengths are:-Concentric Pipes:

135° bend 0.5 metres93° bend 1.0 metres

Twin Flue Pipe135° bend 0.25 metres91.5° bend 0.50 metres

The elbow connected to the boiler adaptor is not includedin any equivalent length calculations

5. The illustrations opposite show examples of permissibleflue systems.

NOTE: Flue length is measured from point X to Y asshown.

NOTE: Horizontal flue pipes should always be installed with a 1.5° to 3° fall fromthe terminal to allow condensate to run back to the boiler.

Y

X

This bend is equivalent to1 metre

Total equivalent length (upto 10m) =

A+B+C+2x90°Bends

B

AC


19

8.0 Flue Options


VerticalFlues

VerticalFlues(Twin Pipe)

Y

X

Y

X

8.2 Twin & Vertical Flue Systems

1. Maximum permissible equivalent flue lengths are:-

(60/100) (80/125)Vertical Concentric 10 metres 20 metresVertical Twin Pipe 15 metres

2. Any additional “in line” bends in the flue system must betaken into consideration. Their equivalent lengths are:-Concentric Pipes:

135° bend 0.5 metres93° bend 1.0 metres

Twin Flue Pipe135° bend 0.25 metres91.5° bend 0.50 metres

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

NOTE: Flue length is measured from point X to Y asshown.

The total equivalent length for this example is= 6.5 metres.

1m extension

45°bend

91.5°bend

1m

0.25m

0.5m

5

2

2

5.0m

0.5m

1.0m

AIR DUCTNo of

fittings/pipesSub totalEquivalent

Length Value

Equivalent Length Air Duct = 6.5m

1m extension

45°bend

91.5°bend

1m

0.25m

0.5m

5

2

2

5.0m

0.5m

1.0m

FLUE DUCTNo of

fittings/pipesSub totalEquivalent

Length Value

Equivalent Length Flue Duct = 6.5m

Y

X

C

RoofTerminal

A

B

660mm


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

All vertical and angled runs must be included,measured from the boiler adaptor (point X) to thejoint with the flue terminal (point Y). One 91.5°bend or two 45° bends can be included withoutreduction of the flue length.

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

1 metre for each 91.5° elbow0.5 metre for each 45° elbow

20

8.0 Flue Options


Key Accessory Size Code NoFLUE GROUP AConcentric Flue System 100mm diameterA Horizontal Flue Terminal (incl elbow) 5118489A2 Telescopic Flue (inc. elbow) 315-500mm 5119654A3 Telescopic Internal Flue Kit 315-500mm 5119654B Flue Extension 1000mm 5111074C Flue Bend 93° 5111075D Flue Bend (pair) 135° 5111085U Pipe Support (painted) 100Ømm 5111080R Vertical Flue Adaptor 5111070P Wall Liner 5111067S Flue Terminal Deflector 5111068

FLUE GROUP NTwin Flue System 80mm diameterE Flue Extension (pair) 1000mm 5111087F Flue Bend (pair) 90° 5111072G Flue Bend (2 pair) 135° 5111086J Vertical Flue Boiler Adaptor Kit 5111079H Vertical Flue Adaptor 5111084W Pipe Support (pair) 80mm 5111081Y Twin Flue Termination Kit

(horizontal termination) 80mm 5120172

FLUE GROUP GConcentric Flue System 80/125mm diameterA4 Horizontal Flue Kit 5118580B Straight Extension Kit 1000mm 5118584D Bend Kit (pair) 135° 5118597C Bend 91.5° 5118588X Pipe support 125mm 5118610

FLUE GROUP A, N, GVertical Flue KitsK1 Vertical Flue Terminal 5118576L Pitched Roof Flashing 25°/45° 246141

Pitched Roof Flashing 35°/55° 246142M Roof cover plate 246143N Flat roof flashing 246144

A

A2

B

K1

RDC

N

U,W,X

S

L

H

J

M

E

G F

P

8.3 Flue Accessories

A3

A4

21

8.0 Flue Options


For Twin Flue Systems fit the adaptors as follows:-

8.4 Flue Duct Adaptor

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

8.5 Air duct adaptor

1. Undo the screws securing the blanking plate to the boilertop panel. Discard the plate.

2. There are three restrictor plates supplied in the kit. For12kW models use the one marked ‘23’ and one marked ‘27’for 15 & 18kW models. The third restrictor is for 24 &32kW models and MUST be positioned as shown in thediagrams below.

3. Take one of the gaskets supplied in the kit and place onthe boiler top panel.

4. Align the appropriate restrictor as shown. Position thesecond gasket over the restrictor.

5. Using the screws previously removed secure the inletadaptor to the top panel.

6. Continue to fit the twin flue system.

Flue Duct Adaptor

Inlet Adaptor

Gasket

Restrictor

Gasket

Blanking Plate

12 kW models

15/18 kW models

24 kW models

32 kW models

Position of Restrictor

22

8.0 Flue Options


8.6 For Roof Terminals

1. In the case of a pitched roof 25 - 50 degrees, position the leadtile to replace/flash over existing roof tiling. Make an aperture inthe roof suitable for the lower tube of the roof terminal andensure the integrity of the roof cover is maintained. Theadjustable plastic collar can either be positioned on the lead tileor the lower tube of the roof terminal prior to the finalpositioning of the vertical flue through the tile. Check the collar iscorrectly located to suit required roof pitch (either 25° to 38° or37° to 50°). From inside the roof adjust the flue to a verticalposition and secure to the roof structure with the clamp supplied.

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

IMPORTANT: If the boiler is not fitted immediately after the fluesystem, temporary precautions must be taken to prevent rainentry into the room of installation. Any precautionary measuresmust be removed prior to commissioning the boiler.

8.7 Flue Dimensions

The standard horizontal telescopic flue kit allows for lengthsbetween 100mm and 685mm from elbow to terminal (Fig. 11).

The maximum permissible equivalent flue length is: 10 metres (60/100 system)20 metres (80/125 system)

8.8 Flue Trim

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

8.9 Terminal Guard (Fig. 12)

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

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

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

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

8.10 Flue Deflector

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

Fig. 11

Fig. 12

100mm

685mm

Push Fit Adaptor

Air Duct

Flue Duct

Cut the sameamount off theAir Duct &Flue Duct

Approx1425mm

Flue Deflector

23

9.0 Plume Displacement


9.1 Plume Displacement Kit (Fig. 14)

Kit No 5118638 (5121367 without elbow)Content of kit

1 0.9m 60/100 Concentric Flue1 1m 60 Dia Exhaust Flue Pipe1 Adaptor2 60 Dia Support Brackets1 93° Elbow/Plume Outlet Assembly1 Flexible Flue Trim3 “O” Rings1 ‘Jubilee Clip1 Elbow

1. This kit is recommended for installations where thecondensate plume emitted from the flue may cause a nuisanceor affect the surroundings.

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

3. The plume outlet must always be at least 45° to the wall,with the ‘peak’ uppermost to prevent rain entry (Figs. 15 &16), and be at least 2 metres above ground level. It must besecured as shown in Fig. 10. The plume outlet must also be atleast 500mm from the air inlet in any direction (Fig. 16).

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

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

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

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

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

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

NOTE: Permitted positions of the plume outlet relative todoors, windows etc. are the same as for conventionalconcentric flues as detailed in the main Installation &Servicing Instructions and BS5440 Pt. 1. It is NOTnecessary to fit a terminal guard over the air inlet or theplume outlet.

Air Inlet at Bottom

‘Peak’ Uppermost

Fig. 15

Fig. 16

500mm Min.

45°

45°Outlet must be atleast 45° fromwall face

93° Elbow/PlumeOutlet Assembly

60Ø ExhaustFlue Pipe

60Ø SupportBracket

60Ø SupportBracket

Flexible FlueTrim

60/100ØConcentric Flue

Adaptor

O Ring

O Ring

O Ring

‘Jubilee’ Clip

0.9 metres

Fig. 14

Fig. 13

24



Concentric 60/100 Flue

60Ø Exhaust

X

Y

Fig. 17

2

0

2

4

6

8

10

12

14

60 Ø

Exh

aust

(m

etre

s) X

Concentric 60/100 Flue (metres) Y

0

16

1 3 4 65 7 98 10 1211 13 14

12/15/18

32

24

Fig. 18

2

0

2

4

6

8

10

12

14

60 Ø

Exh

aust

(m

etre

s) X


0

16

1 3 4 65 7 98 10 1211 13 14

12/15/18

32

24

2

0

2

4

6

8

10

12

14

60 Ø

Exh

aust

(m

etre

s) X


0

16

1 3 4 65 7 98 10 1211 13 14

12/15/18

32

24

Flue Length - Worked ExamplePotterton Promax System 32 HE

In Fig. 18 opposite an additional 93° bend and pair of 45°bends have been included in the 60Ø exhaust.Also 3 straight extension pieces have been used.

To calculate total length:-Length of 60Ø supplied in kit = 1 metre3 x 1 metre Extensions = 3 metres1 x 93° Elbow = 1 metre2 x 45° Elbow = 1 metre (0.5 metres each)

Total 60Ø = 6 metres

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

Concentric Flue

SupportBracket

45° Elbow

93° Elbow

1 metre Extension

1 metre supplied in kit

Additional Accessories

A - 93° Elbow 5117381B - 45° Elbow (Pair) 5117382C - 1 metre 60Ø Extension 5117380

9.2 Determining Permissible Lengths

In the graph the solid line diagonal represents therelationship between the concentric flue assembly (and anyextensions) and the 60Ø exhaust (and any extensions oradditional bends).

Example 1 - Not PermissibleIf, for instance, a concentric length of 5 metres was requiredand the 60Ø exhaust needed to be 6 metres the graphshows that this combination would NOT be permissible asthe intersection point would be above the solid diagonal line.

Example 2 - Flue Lengths OKWhere both lengths have been determined they can beapplied to the graph to check that the installation ispermissible. For example, if it was known that 2 metres ofconcentric flue and 4 metres of 60Ø exhaust were required,the values could be applied to the graph as shown inExample 2.. As the point of intersection of the dotted lines isbelow the solid diagonal line, the combination of lengths isshown to be acceptable.

Example 3 - Flue Lengths OKIn the example shown, assume that the concentric part ofthe flue needs to be 2.3 metres long. Find the position of‘2.3’ on the horizontal axis of the graph and then projectupwards to the solid diagonal line. This is represented by thevertical thick dotted line. Where this dotted line intersectswith the solid diagonal line on the graph, project across tothe vertical axis. As can be seen this corresponds with 6metres. Therefore, the total equivalent length of the 60Øexhaust can be up to 6 metres. Any bend equivalencies mustbe accounted for i.e. 93° bends are equal to 1 metre, each13 5° bend to 0.5 metres.

Example 1

Flue Lengths - Not PermissibleExample 2

Flue Lengths - OK

Example 3

Flue Lengths - OK

25



Min. 2 metres

Fig. 19

Flue Trim

Position of ‘Jubilee’ Clipscrew

Fig. 24

30mm

30mm Fig. 21

Fig. 23

Fig. 20

Fig. 22

Adaptor

Spigot

9.3 General Fitting Notes

1. Cut a hole in the external wall which the concentric flueassembly will pass through. The hole should allow the flueto fall back to the boiler at an angle of 3°.

2. When completed the terminal must be at least 2 metresabove ground level (Fig. 19).

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

4. Insert the concentric assembly through the hole fromoutside the building.

5. If required, the flexible flue trim should be fitted prior tothis as it cannot be fitted after. Use the large ‘Jubilee’ clip tosecure the trim to the flue (See Fig. 20, trim showndotted), with the screw part of the clip at the bottom.

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

7. Ensure that the concentric assembly and any extensionsfall back to the boiler at an angle of 3° and that theexternal air inlet is to the bottom.

8. Use suitable brackets to support the concentricassembly and any extensions, and make good inside andoutside.

9. The 60Ø exhaust can now be fitted. Slide the adaptorover the plain end of the 60Ø exhaust (Fig. 22) and engagethe exhaust in the terminal. Slide the adaptor down overthe spigot. Mark and drill the adaptor, using a 2mm bit, asshown in Fig. 21. Secure the adaptor to the spigot usingone of the screws supplied.

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

11. Determine the position of the 60Ø exhaust and markon the wall a suitable position for the support bracket. Ifextensions are being used, a support bracket is supplied ineach kit.

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

13. Mark and drill the 60Ø exhaust, using a 2mm bit, asshown in Fig. 23. Complete the installation of the 60Øexhaust, securing in the brackets.

14. Fit the 93° elbow/plume outlet and secure with thetwo remaining screws supplied. Ensure the plume outlet isat least 45° to the wall and that the ‘peak’ is uppermost(Fig. 24).

26



9.3 General Fitting Notes (cont.)

15. For aesthetic purposes it is permissible to route the60Ø exhaust in an enclosed box, but the air inlet andplume outlet MUST remain in free air.

16. It is also possible to separate the plume outlet from the93° elbow to allow the flue to be installed as shown in Fig. 25.

17. To do this, first slacken the two screws retaining theplume outlet to the elbow, and remove the outlet (Fig. 26).The elbow can now be used to connect the vertical tohorizontal 60Ø exhaust (Fig. 25). Retighten the screws inthe elbow.

18. The outlet can now be fitted into the female end of an60Ø extension piece. It must be secured using two of thescrews supplied in the bag with the ‘Jubilee’ clip.

19. Mark the female end of the extension at 30mm asshown in two positions, directly opposite each other (Fig. 27).

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

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

22. When the plume outlet is positioned under a balconyor other projection (Fig. 28) it must protrude at least200mm (it is not necessary to extend it further than this).

23. When under balconies or projections it is permissible torotate the concentric flue length up to 70°, clockwise oranti-clockwise (Fig. 29), if there is insufficient space toconnect vertically.

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

25. All other minimum & maximum dimensions must beadhered to, and the air inlet positioned such that it will notbe subjetc to rain entry.

500mm Min.

200mm Min.

30mm

Fig. 26

Fig. 27

Fig. 25

Fig. 28

Plume OutletElbow

70°

Fig. 29

Outlet Spigot

Concentric Flue Length(shown end-on)

27

10.0 Installation


10.1 Unpacking & Initial Preparation

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

1. If pre-plumbing is required turn the unopened cartonover and remove the staples. Open the flaps and removethe cardboard sheet, template and wall plate.

2. The wall plate can then be used to pre-plumb the system,and the carton turned back over.

3. Alternatively, remove the staples from the top of thecarton, open the flaps and remove the cardboard sheet.Remove the polystyrene side pieces. Two people can thenlift out the boiler.

Note: A small amount of water may drain from the boilerin the upright position.

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

5. Mark the position of the two most suitable fixing slots forthe wall plate and boiler lower fixing holes. It is preferable touse the vertical fixing slots.

6. Mark the position of the centre of the flue hole (rearexit). For side flue exit, mark as shown (Fig. 34).

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

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

9. Drill the wall as previously marked to accept the wallplugs supplied. Secure the wall plate using the fixing screws.

10. Using a spirit level ensure that the plate is level beforefinally tightening the screws.

11. Connect the gas and water pipes to the valves on thewall plate using the copper tails supplied. Ensure that thesealing washers are fitted between the connections.

10.2 Flushing

1. Connect a tube to the central heating flow or return pipe(Fig. 35).

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

Fig. 35

145mm

For Side Flue Exit

Central Heating Return

Flushing TubeWall Plate

Fig. 34

28

10.0 Installation


10.3 Fitting The Boiler

1. Lift the boiler using the Lifting Points as shown by theshaded areas (Fig. 36). The boiler should be lifted by TWOPEOPLE. Engage the slots at the top rear of the boiler on thewall plate (Fig. 36) (see Safe Manual Handling page 5).

2. Ease the boiler forwards and remove the sealing caps fromthe boiler connections.

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

3. Insert the sealing washers between the valves and pipeson the wall plate and the boiler connections. The rubberwashers must be used on the gas connection.

4. Tighten all the connections.

10.4 Fitting the Pressure Relief Discharge Pipe (Fig. 38)

1. Remove the discharge pipe from the kit.

2. Determine the routing of the discharge pipe in the vicinityof the boiler. Make up as much of the pipework as ispractical, including the discharge pipe supplied.

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

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

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

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

10.5 Condensate Drain (see section 7.7)

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

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

2. The connection will accept 21.5mm (3/4in) plastic overflowpipe which should generally discharge internally into thehousehold drainage system. If this is not possible, dischargeinto an outside drain is acceptable.

Fig. 38

Fig. 36

Pressure Relief Valve

Wall Plate

Discharge Pipe

Suggested Lifting Points

shown as shaded area

29

10.0 Installation


Wall Thickness

(X)

Wall Thickness

(X)

Flue Elbow

Fig. 39

Fig. 41

Adaptor

Apply Lubricant forease of assembly.

Ensure Elbow is fullyengaged into BoilerAdaptor

100mm

685mm

20mm

Indicator line

Fig. 40

10.6 Fitting The Flue

HORIZONTAL FLUE

1. The standard flue is suitable for lengths between 100mmminimum and 685mm maximum, as measured from theedge of the flue elbow outlet to the joint between theterminal and air duct (Fig. 39).

2. Locate the flue elbow on the adaptor at the top of theboiler. Set the elbow to the required orientation (Fig. 41).The elbow is fully engaged when there is a distance of20mm from the adaptor to the indicator line (Fig. 39a).

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

3. Measure the distance from the outside wall face to theelbow. This dimension will be known as ‘X’ (Fig. 40).

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

IMPORTANT: Check all dimensions before cutting.

5. Mark dimension ‘Y’ on the flue as shown (Fig. 42).Carefully cut the waste material from the flue, ensuring thatthe ducts are square and free from burrs.

Fig. 42

Y

Flue

Waste

Fig. 39a

30

10.0 Installation


Slots at bottom

Fig. 44

Fig. 45

Apply Lubricant forease of assembly.Ensure Flue is fullyengaged into FlueElbow

Adaptor

Apply Lubricant forease of assembly.

Ensure Extension isfully engaged intoBoiler Adaptor

25mm

Extension

Cut End

Fig. 46

Tape

Fig. 47

10.6 Fitting the Flue (Cont)

6. The inner flue duct support bracket may be in the wasteportion of the flue. In this case retrieve the bracket beforediscarding the waste.

7. Take the inner flue support bracket (if not already fitted)and engage it over the flue duct. This will centralise the flueand air ducts, and ease assembly (Fig. 43).

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

9. Draw the flue back through the wall and engage it in theelbow. It may be necessary to use soap solution or similarto ease assembly of the elbow adaptor and flue (Fig. 44).

10. Ensure that the terminal is positioned with the slots tothe bottom (Fig. 45).

IMPORTANT: It is essential that the flue terminal is fittedas shown to ensure correct boiler operation and preventwater entering the flue.

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

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

CONCENTRIC VERTICAL FLUE

13. Once the length of the vertical concentric extension hasbeen determined mark and carefully cut off the excessmaterial. The cut end MUST be square and free of burrs toensure correct insertion into the boiler adaptor.

14. Measure 25mm from the end of the flue extension andapply a length of tape around the outer duct (Fig. 46).

15. Engage the extension into the adaptor up to thisposition (Fig. 47). Once the installation of the flue iscomplete and all support brackets are securely in placeremove the tape.

Inner Flue Support Bracket

Fig. 43

31

10.0 Installation


10.7 Making The Electrical Connections

The boiler is fitted with a 1.3m length of 3 core of cable.This can be connected to the fused 3A 230V 50HZ supply.

NOTE: Both the Live and Neutral connections are fused.

To connect an external control proceed as follows:-

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

2. Completely undo the screws securing the facia panel andhinge it down (Fig. 48).

3. Undo the terminal block cover securing screw andremove the cover (Fig. 48).

4. Slacken the unused cable clamp on the LH side of theboiler chassis (Fig. 49). Insert the external control wiringthrough the clamp and route it to the terminal block.

5. Refer to the instructions supplied with the control.

IMPORTANT: The external control MUST be suitablefor 230V switching and fused 3A maximum.

6. Remove the link between terminals 1 & 2. The switchedoutput from the external control must be connected toterminal 2. (Fig. 50).

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

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

10.8 Preliminary Electrical Checks

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

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

Always fit fast blow 2A fuse

Fused supply 3A230V ~ 50Hz

Neutral (blue)

Earth (green/yellow)

Live (brown)

1

2

230V

br

b

g/y

bk

bk

Fig. 49

Fig. 50

Fig. 48

Terminal Block

Fuses

Cable Clamp

Terminal Block Cover

Facia Panel

32

11.0 Commissioning


11.1 Commissioning the Boiler

1. Reference should be made to BS 5449 Section 5 whencommissioning the boiler.

IMPORTANT: The heat exchanger air vent on top of theboiler (Fig. 51) MUST be opened before filling the primarysystem.

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

3. Open the screw on the automatic air vent on the pumpbody (Fig. 52).

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

5. Pressurise the system to 1.5 bar then close and disconnectthe filling loop.

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

7. Test for gas soundness.

8. Hinge the facia panel upwards and refit the case frontpanel. Tighten the securing screws.

9. Turning the temperature control knob will set the relevanttemperature. When the knob is turned the display will alterand show the selected temperature. After a few seconds thedisplay reverts to show the current boiler temperature (Fig. 54).

PumpAutomatic Air

Vent

Pressure Gauge

Screw

bar

0

1

2

3

4

Fig. 52

Selector Switch

Central Heating Temperature Control

Calibration Control

Reset

bar

0

1

2

3

4

Pump

Fig. 54

Fig. 53Display

Heat ExchangerAutomatic Air Vent

Fig. 51

33

11.0 Commissioning


11.2 Checking

1. The gas valve is factory set and the burner pressure cannotbe measured as it is altered by suction of the fan andmodulates as demand on the boiler alters. The gas supplypressure should be 20mb.

2. If necessary the gas rate may be checked after running theboiler for 10 minutes with any other appliances and pilotlights turned off.

3. Ensure that the integral timer and any external controls arecalling for heat, and the selector switch is in the centralheating and hot water position ( ). The current boilertemperature is shown on the display.

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

5. Turn both temperature control knobs fully anticlockwise,then quickly turn the Calibration Control knob 1/4 clockwisetwice and back fully anticlockwise (Fig. 55).

6. The display will now alternate between ‘SF’ and thecurrent boiler temperature and both green LEDs will flash(Figs. 56 & 57).

7. Turn CH temperature control knob fully clockwise. As theknob is turned the display will change from ‘0’ to ‘00’ (Fig. 58)indicating maximum rate, then revert to ‘P’ alternating withthe current boiler temperature (Figs 59 & 60).

8. A gas rate measurement may now be made. Approximatevalues are:-

12 model 1.31 m3/h

15 model 1.69 m3/h

18 model 1.95 m3/h

24 model 2.6 m3/h

32 model 3.48 m3/h

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

10. The function can be disabled at any time by turning theCalibration Control knob.

Selector Switch Display

Reset

bar

0

1

2

3

4


Calibration Control

Fig. 56 Fig. 57

Fig. 58

Fig. 59 Fig. 60


Calibration ControlFig. 55

x 2

34

12.0 Completion


12.1 Completion

1. Instruct the user in the operation of the boiler andsystem including the integral timer, explaining theoperational sequence.

2. Set the central heating and hot water temperaturecontrol knobs to the requirements of the user.

3. Carefully read and complete all sections of theBenchmark Commissioning Checklist at the rear of thispublication that are relevant to the appliance andinstallation. These details will be required in the event ofany warranty work. The publication must be handed to theuser for safe keeping and each subsequent regular servicevisit recorded.

4. For IE, it is necessary to complete a “Declaration ofConformity” to indicate compliance with I.S. 813. Anexample of this is given in I.S. 813 “Domestic GasInstallations”. This is in addition to the BenchmarkCommissioning Checklist.

5. Hand over the Users Operating, Installation andServicing Instructions giving advice on the necessity ofregular servicing.

Fig. 61Facia Panel

Case Front Panel

35

13.0 Servicing


13 .1 Annual Servicing

1. For reasons of safety and economy, it is recommended thatthe boiler is serviced annually.Servicing must be performed by a competent person.

If a combustion analyser is available the CO2 can bechecked and adjusted - see Section 15.0.If the reading is acceptable, and a visual inspection of theappliance is satisfactory, it is not necessary to perform a fullstrip - down.

2. After servicing, complete the relevant Service IntervalRecord section of the Benchmark Commissioning Checklist atthe rear of this publication.

3. Ensure that the boiler is cool.

4. Ensure that both the gas and electrical supplies to theboiler are isolated.

5. Slacken the screws securing the facia panel. Lift theoutercase panel so that its securing tabs are clear of the facia.Remove the panel, allowing the facia to hinge down (Fig. 62).

6. Remove the screws securing the inner door panel. Lift thepanel slightly to disengage it from the studs on top of the case(Fig. 63).

7. Unscrew the sump from the bottom of the condensate trapassembly (Fig. 64).

8. Remove any deposits from the sump and trap. Clean asnecessary and replace the sump.

Case Front Panel

Fig. 62

Facia Panel SecuringScrews

Fig. 63Inner Door

Panel

Fig. 64

CondensateTrap

Sump

36

13.0 Servicing


13.1 Annual Servicing (Cont)

7. Undo the nut on the gas inlet pipe to the venturi (Fig. 65)and pull the sensing pipe off the fan.

8. Disconnect the electrode leads, noting their position, andthe fan electrical plugs (Fig. 66).

9. Undo the four nuts retaining the combustion box coverto the heat exchanger.

10. Carefully draw the fan, collector and cover assemblyforward, being careful to retain the injector in the venturi(Figs. 65 & 66).

11. Clean any debris from the heat exchanger and checkthat the gaps between the tubes are clear.

12. Inspect the burner, electrodes position and insulation,cleaning or replacing if necessary. Clean any dirt or dustfrom the air box.

13. Reassemble in reverse order.

NOTE: The sensing pipe must be reconnected to thefan, not the venturi.

Fig. 66

Fig. 65 Gas Inlet Pipe

Venturi

Injector

Fan, Collector and CoverAssembly

ElectrodeLeads

4 ± 0.5

10 ± 1

7.5 ± 1

Electrode Position

Viewing Window

Burner

37

14.0 Changing Components


IMPORTANT: When changing components ensure thatboth the gas and electrical supplies to the boiler areisolated before any work is started. When thecomponent has been changed turn the selector switchfully anticlockwise against the spring pressure to thereset position and hold for 5 seconds to reset the boilerbefore recommissioning.

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

14.1 Igniter (Fig. 67)

1. Disconnect the igniter feed plug and the electrode leads,noting their positions.

2. Undo the screw securing the bracket to the boiler.

3. Remove the igniter and transfer the bracket to the newcomponent.


14.2 Spark and Sensing Electrodes (Fig. 68)

1. Disconnect the electrode leads, noting their positions.

2. Remove the retaining screws securing each of theelectrodes to the combustion box cover and remove theelectrodes.

3. Check the condition of the sealing gaskets and replace ifnecessary. Reassemble in reverse order.

Fig. 67

Igniter

Igniter FeedPlug

ElectrodeLeads

Bracket

Fig. 68

SparkElectrode

SensingElectrode

ElectrodeLeads

38



14.3 Fan (Fig. 69)

1. Undo the nut on the gas inlet pipe to the venturi (Fig. 70)and pull the sensing pipe off the fan.

2. Disconnect the electrode leads, noting their position anddisconnect the fan electrical plugs.

3. Undo the screws securing the collector to the extensionpiece.

4. Remove the collector and fan assembly, being careful toretain the injector in the venturi.

5. Undo the screws securing the fan to the venturi and fit thenew fan. On 18 models ONLY transfer the fan inlet flange tothe new fan. Replace the seal if necessary.

6. Examine the burner gasket and replace if necessary.

7. Reassemble in reverse order, ensuring that the injector isin place and the sensing pipe is connected to the fan.

14.4 Venturi (Fig. 69)

1. Remove the collector and fan assembly as described insection 14.3.

2. Extract the injector from the venturi.

3. Undo the screws securing the fan to the venturi and theventuri to the collector.

IMPORTANT: When fitting the new venturi, ensure thearrows on it’s base point into the collector (Fig. 71).

4. Examine the seals and burner gasket, replace if necessary.

5. Reassemble in reverse order, ensuring that the injector isin place.

14.5 Injector (Fig. 69)

1. Remove the collector and fan assembly as described insection 14.3.

2. Extract and replace the injector and reassemble in reverseorder.

Cover

Gas Inlet

Fan

Venturi

Injector

Collector

When fitting the venturiensure that the arrow is

pointing forward

Fig. 69

Fig. 70 Gas Inlet Pipe

Venturi

Injector

Fig. 71

Fan Inlet Flange(18 model

ONLY)

39



14.6 Burner (Fig. 72)

1. Undo the screws securing the collector to the venturi andextension piece. Remove this extension piece from thecover (on 24 models).

2. Withdraw the burner from the cover and replace withthe new one.

3. Examine the gasket, replacing if necessary.


14.7 Insulation (Fig. 73)

1. Remove the electrode leads, noting their positions. Alsoremove the electrodes as described in section 14.2.

2. Undo the screws securing the collector to the venturi andthe nuts holding the cover to the heat exchanger. Draw thecollector and cover assembly away.

3. Remove the cover insulation piece.

4. Fit the new insulation carefully over the burner and alignit with the slots for the electrodes.

5. The rear insulation is retained by a screw and largewasher, remove these and draw the insulation out of theheat exchanger.

6. Examine the cover seal and replace if necessary.

Fig. 72

Cover

Burner

Gasket

Extension Piece(Not on 28 model)

Collector

Venturi

HeatExchanger

RearInsulation

CoverInsulation

Seal

Collector

SparkElectrode

SensingElectrode

ElectrodeLeads

Venturi

Fig. 73

40



14.8 Flue/Heat Exchanger Thermostat Sensor (Fig. 74)

1. Ease the retaining tab on the sensor away and disconnectthe electrical plug.

2. Turn the sensor 90o anticlockwise to remove - it is abayonet connection.


14.9 Water Pressure Sensor (Fig. 76)

1. Drain the primary circuit.

2. Disconnect the two wires from the sensor.

3. Undo the nut on the flow pipe securing and sealing thesensor.

4. Remove the sensor, examine the sealing washer, replacing ifnecessary.

5. Reassemble in reverse order. The component is notpolarised - either wire will fit each terminal.

14.10 Central Heating Temperature Sensor (NTC) (Fig. 75)


2. Unscrew the sensor from it’s pocket and reassemble inreverse order. The plug will only fit one way.

14.11 Safety Thermostat (Fig. 75)

1. Pull the plug off the thermostat.

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

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

14.12 Return Heating Temperature Sensor (Fig. 77)


2. Prise the sensor retaining clip off the pipe and remove thesensor from the clip.


Central HeatingTemperature Sensor

Safety Thermostat

Flow Pipe

Fig. 75

Flue/Heat ExchangerThermostat Sensor

ElectricalPlug

Fig. 74

Fig. 77

Return HeatingTemperature Sensor

Fig. 76

Pressure Sensor

41



14.13 Pump - Head Only (Fig. 78)

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

2. Undo the screw on the pump wiring cover and removethe cover. Using a suitable flat bladed screw driver press thecable securing levers downwards to release each wire afternoting their position.

3. A standard replacement Grundfos 15-60 head can nowbe fitted. Connect the pump wiring to the new head. Thepump speed must be set to 3 (Fig. 79).


14.14 Pump - Complete (Fig. 80)


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

3. Undo the screw on the pump wiring cover and removethe cover. Using a suitable flat bladed screw driver press thecable securing levers downwards to release each wire afternoting their position.

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

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

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

14.15 Automatic Air Vent (Fig. 80)

1. Drain the primary circuit and unscrew the automatic airvent from the pump body.

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


Pump Setting

Socket HeadedScrew

Pump Head

Pump Body

Automatic AirVent

Fig. 78

Fig. 80

Fig. 79

Pump WiringCover

Pump WiringCover

42



14.16 Pressure Gauge (Figs. 81 & 82)

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

2. Undo the screws securing the gauge retaining bracket.

3. Remove the bracket and gauge assembly. Depress thebarbs on the side of the gauge and remove the retainingbracket.

4. Examine the sealing washer, replace if necessary.


14.17 Pressure Relief Valve (Fig. 83)


2. Disconnect the discharge pipe from the valve. Using asuitable hexagon key undo the grub screw sufficiently torelease the valve.

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

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

Pressure Gauge

Gauge RetainingBracket

Fig. 82

Fig. 81

Fig. 83

Pressure GaugeCapillary

‘O’ RingSeal

Discharge Pipe

Grub Screw

43



14.18 P.C.B. (Fig. 85)

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

2. Completely undo the screws securing the control boxcover and release the cover retaining barbs from their slots.Disengage the rear of the cover from the control box hingepin (Fig. 84).

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

4. Undo the securing screws and remove the P.C.B. Transferthe control knob drive pins to the new P.C.B. and turn themfully anticlockwise.

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

14.19 Selector Switch (Fig. 85)

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

2. Completely undo the screws securing the control boxcover and release the cover retaining barbs from their slots.Disengage the rear of the cover from the control box hingepin (Fig. 84).

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

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

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

Control Box Cover

P.C.B.

SelectorSwitch

Facia

Selector Switch Knob Temperature Control Knobs

Fig. 84

Fig. 85

Drive Pins

44



14.20 Gas Valve (Fig. 86)

IMPORTANT: After replacing the valve the CO2 must bechecked and adjusted as detailed in Section 15.0Combustion Check. Only change the valve if a suitablecalibrated combustion analyser is available

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

2. Remove the screws securing the inlet pipe flange to theboiler bottom panel.

3. Pull off the earth lead and sensing pipe.

4. Undo the nut on the venturi inlet pipe and slacken the nuton the venturi. Ease the pipe aside and remove the gas valve.

5. Remove the outlet adaptor and inlet pipe and transfer themto the new valve. Examine the ‘O’ ring seals, replace ifnecessary.


14.21 Expansion Vessel (Fig. 87)

1. Drain the primary circuit and undo the nut on the vesselconnection pipe.

2. Undo and remove the locknut and spring washer securingthe vessel spigot to the boiler air box.

3. Remove the bracket and vessel from the boiler.

4. Locate the retaining bracket on the upper flange of thevessel and fit to the boiler.


Gas Valve

ValveInlet Pipe

Gas FeedElbow

Fig. 86

Ignition Lead

Expansion Vessel

Boiler Chassis

Lock Nut

SpringWasher

Fig. 87

Retaining Bracket

Sensing Pipe

Venturi InletPipe

Outlet Adaptor

45

15.0 Combustion Check


15.1 Checking the CO2

IMPORTANT: The CO2 must be only be checked andadjusted if a suitable calibrated combustion analyser isavailable.

1. The combustion (CO2) may be checked after running theboiler for several minutes. To do this it is necessary to setthe boiler to ‘Calibration Mode’.

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

3. Turn both temperature control knobs fully anticlockwise,then quickly turn the Calibration Control knob 1/4 clockwisetwice and back fully anticlockwise (Fig. 88).

4. The display will now alternate between ‘SF’ and thecurrent boiler temperature and both green LEDs will flash(Figs. 89 & 90).

5. Turn the CH temperature knob fully clockwise. As theknob is turned the display will change, indicating the fanspeed.

6. The display will show ‘00’, indicating maximum rate, thenrevert to ‘P ‘ alternating with the current boiler temperature(Figs 91, 92 & 93).

7. Remove the plug from the flue adaptor test point. Insertthe analyser probe and allow time for the reading to settle(Fig. 94).

The CO2 should be 8.7% ± 0.2

8. It is possible to alter the CO2 by adjustment of the gasvalve. Remove the plastic cover from the ‘Max Rate’adjustment screw. At maximum rate the ‘Max. Rate’adjustment screw should be turned, using a suitablehexagon key, until the correct reading is obtained (Fig. 95).Turning clockwise will reduce the CO2. Anti-clockwise willincrease the CO2.

9. The CO2 must then be checked at minimum rate. Turnthe CH temperature knob fully anticlockwise. As the knob isturned the display will change, indicating the fan speed.When the display reads ‘ 0’ the boiler runs at minimum rate.

The CO2 should be 8.4% ± 0.2.

10. With the boiler on minimum, the ‘Min. Rate’ adjustmentscrew must be altered, using a suitable hexagon key, afterremoving the cap (Fig. 95). Turning anti-clockwise willreduce the CO2. Clockwise will increase the CO2. If the CO2

is reset at either boiler rate it must be rechecked at theother rate and also adjusted if required.

11. The ‘Calibration Function’ is maintained for 20 minutesunless the maximum CH temperature is exceeded. Thefunction can be disabled at any time by turning theCalibration Control knob.

Selector Switch Display

Reset

bar

0

1

2

3

4


Calibration Control

Fig. 89 Fig. 90

Fig. 91 Fig. 92 Fig. 93


Calibration ControlFig. 88

x 2

Fig. 94

Max RateAdjustment Screw(cover removed)Min Rate

Adjustment Screw(cap fitted)

Gas ValveFig. 95

Flue Adaptor TestPoint

Plug

Analyser Probe

46

16.0 Electrical


- brown- black- blue- white

brbkbw

- green- green / yellow- red

gg/yr

Control PCB

X2 X3

X9

X501

1 21 2 33 44 55 6 7 8 9

X1

1 2

Return Heating Temperature Sensor

Reset Selector Switch

Central Heating NTC Sensor

Fan

Gas Valve

Overheat Stat

FlameSensingElectrode

Pump

Mains Input Linkg/y

b

br

Flue Sensor

X400 X401

gg

bb

r

r b

b

bb

bbr

bk g

b

br

g/y

b

br

b br

br

b

b

b

br

br

br

b

b

br

r bk

r

bk

bk

br

b

b

br

Water PressureSwitch

9 8 7 6 5 4 3 2 1 910 8 7 6 5 4 3 2 1

14

25

31

2

SparkGenerator

IgnitionElectrode

NL

w

g

ab

b

w

16.1 Illustrated Wiring Diagram

47

17.0 Short Parts List


Short Parts List

Key G.C. Description ManufacturersNo. No. Part No.

302 Flue Thermostat 5114747

306 Burner (12/15/18) 5122149

Burner (24) 5114697

Burner (32) 5114698

311 Fan 5114684

315 Igniter Electrode 5114702

316 Sensing Electrode 5114703

415 Pump 248042

419 Water Pressure Switch 5114748

420 Overheat Thermostat 5114729

421 NTC Sensor 5114725

422 Gas Valve 5114734

434 NTC Sensor (Return) 5114725

503

PCB 12 5122455

PCB 15 5122457

PCB 18 5122458

PCB 24 5118297

PCB 32 5122459

504 Pressure Gauge 248090

306

315 316

311

422 419

415

302 421 420

503504

434

48

18.0 Fault Finding


NOTE: When instructed to turn theselector to the reset position turn theselector switch fully anticlockwise againstthe spring pressure to the reset positionand hold for 5 seconds to reset theboiler.

18.1 Initial Fault Finding Checks

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

2. Electrical supply = 230V ~ 50 Hz.

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

4. The preferred minimum gas pressure is 20 mbar.

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

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

6. Ensure all external controls are calling for heat and checkall external and internal fuses. Before any servicing orreplacement of parts, ensure the gas and electrical suppliesare isolated.

18.2 Error Codes

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

2. The codes are either two or three digit, preceded by theletter 'E'. For example, code E133 will be displayed by 'E1'alternating with '33'. E20 is shown as 'E' then '20'

E20 and E28 indicate faulty components.

E110 shows overheat of the primary water and E130overheat of the flue system.

E119 is displayed when the primary water pressure is lessthan 0.5 bar.

E133 indicates that the gas supply has been interrupted,ignition has failed or the flame has not been detected.

E125 is displayed in either of two situations:-i) If within 15 seconds of the burner lighting the boilertemperature has not changed by 1°.ii) If within 10 minutes of the burner lighting the boilertemperature twice exceeds the selected temperature by 30°.In these instances poor primary circulation is indicated.

3. By turning the selector switch to the 'Reset' position for aminimum of 5 seconds when E110, E130 & E133 aredisplayed it is possible to relight the boiler.

4. If this does not have any effect, or the codes are displayedregularly further investigation is required.

Central Heating NTC FaultFlue NTC Fault Safety Thermostat OperatedWater Pressure Switch Not OperatedCirculation Fault (Primary Circuit)Flue NTC OperatedInterruption Of Gas Supply or Flame FailureFan or Fan Wiring FaultPre-Circulation Fault

E20E28E110E119E125E130E133E160E193

Table Of Error Codes

49

18.0 Fault Finding


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

Turn selector switch to The display illuminates

Error 20, 28 or 50 flashing

Error 119 flashing

Burner lights

Error 110 flashingError 130 flashingError 133 flashing

Turn Central Heatingthermostat to Maximum.

Pump runs

Fan runs

Spark at ignition electrodes forup to 5 seconds and for 3

attempts

3-way valve is open to CentralHeating circuit

Go to section ‘A’

Go to section ‘E’

Ensure all controls andintegral clock are calling for

heat

Go to section ‘K’

Go to section ‘B’

Error 160 flashingGo to section ‘D’

Error 133 flashing

Burner does not stay alightsafter 5 seconds

Error 133 flashingGo to section ‘I’

Operation sequencesuccessful

If the error 110 is still flashing.Go to section ‘J’

Fan runs at correct speed

YES

YES

NO

NO

NO

YES

YES

YES

YES

YES

YES YES

YES

NO

YES YES

YES

YES

NO

NO

NO

NO

NO

Burner output modulates tomaintain the temperature set

Burner goes out

Go to section ‘C’

Ensure controls are set todemand and verify the

contacts are closed

Error 160 flashingGo to section ‘L’

YESGo to section ‘H’

Turn the selector switch toreset

Go to section ‘F’

Error 130 flashingGo to section ‘M’

YES

Check the Central HeatingNTC sensor

Go to section ‘E’

Fan stops after 10 secondsPump continues to run for 3

minutes (room thermostat open)

NO

NO

YES

NO

YES YES

Turn the selector switch toreset position for 5 seconds

NO

Error E125 or E193 flashingEnsure that primary

circulation is OK & thatthere is no blockage

YES

50

18.0 Fault Finding


Fault Finding Solutions Sections

Is there 230V at:

Is there 230V at:

Main terminals L and N Check electrical supply1. NO

Main terminal fuse Replace fuseReplace PCB

Displayilluminated

2. NO

PCB - X1 connectorterminals 1,2

Check wiring3. NO

NO

A

Pump Replace pump1. YES

PCB - X3 connector terminals 3 & 4 Replace PCB2. NO

Change pump supply cable

YES

B

CH system pressure less than 0.5 bar Re-pressurise system1. YES

Check the tap of the automatic airvent is opened

Open the automatic air vent2. NO

C

1.

NO

YESFan connections correct at fan. PCB -X2 connector, is 230V AC acrossterminals 5 & 7

Fan jammed or faulty winding

Replace PCB

Replace fanYES

D

If pump jammed, release NO

NO

Replace waterpressure switch

Check connection water pressureswitch terminalCOM - NO and PCB connectorX400 terminals 3,4

YES

51

18.0 Fault Finding


Temperature sensors faulty.Cold resistance approximately10kΩ @ 25° C (DHW and CH sensors)20kΩ @ 25° C (Flue sensor)(resistance reduces with increase in temp.)

NO

EReplace sensor

Gas at burner Ensure gas is on and purged

Replace PCB

Replace gas valvePCB - X3 connector is 230V AC across

terminals 1 & 2YES

NO

NO

F

Replace PCB

G

Check and correct if necessary1. Ignition electrode and lead2. Electrode connection3. Spark gap and position

voltage at PCB - X2 connector is230V AC across terminals 2,5Check wiring

YES

NO

Replace igniterYES

H

YES

1.

Ensure that the Hall Effect Sensor is in position.Check the connection between the PCB - X400connector terminals 3,6,7 and the electronic sensor

Check the voltage between red wire and bluewire is more than 5V DC

NO

Replace PCB

Check and correct the connection of thetube between the venturi and gas valve

Replace HallEffect Sensor

YES

1.

2.

4 ± 0.5

10 ± 1

7.5 ± 1

Electrode Position

Viewing Window

Burner


18.0 Fault Finding

Check and correct if necessary1. The mechanical set of the gas valve(CO2 values - see instruction)2. Flame sensing electrode and lead connections3. Flame sensing electrode position

Flame current should be more than 0.5 μAReplace PCB

Replace PCB

YES

YES

Replace flame sensing electrodeNO

Check the gas supply pressure:For Natural Gas greater than

10 - 11 mbar

I

Replace safety thermostatYESNOOverheat thermostat operated or

faulty, i.e. continuity acrossthermostat terminals

Allow to cool. Continuityacross thermostat terminals

more than 1.5 ohm

J

K

L

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

1. YESReplace fan

Temperature sensors faulty.Cold resistance approximately10kΩ @ 25° C (CH sensor)20kΩ @ 25° C (Flue sensor)(resistance reduces with increase in temp.)

NOReplace sensor

YESIf pump is running the heat exchanger could beobstructed

Replace heat exchanger

1.

2.

1.

2.

1.

53

19.0 Notes


1 1

1.0 Introduction


CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes

TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT

TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER COMBI BOILER

HEATING ZONE VALVES FITTED NOT REQUIRED

HOT WATER ZONE VALVES FITTED NOT REQUIRED

THERMOSTATIC RADIATOR VALVES FITTED

AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS?

THE SYSTEM CLEANER USED

THE INHIBITOR USED

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

GAS RATE ft3/hr

BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

CENTRAL HEATING FLOW TEMPERATURE °C

CENTRAL HEATING RETURN TEMPERATURE °C

FOR COMBINATION BOILERS ONLY

HAS A WATER SCALE REDUCER BEEN FITTED? YES NO

WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE ft3/hr

MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

COLD WATER INLET TEMPERATURE °C

HOT WATER OUTLET TEMPERATURE °C

WATER FLOW RATE lts/min

FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS? YES

FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING

THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS

THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONEDIN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS

IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2 RATIO READING? N/A YES CO/CO2 RATIO

THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER

THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER

m3/hr

m3/hr

COMMISSIONING ENG’S NAME PRINT CORGI ID No.

SIGN DATE

BOILER SERIAL No. NOTIFICATION No.

BENCHMARK No.

GAS BOILER COMMISSIONING CHECKLISTC O L L E C T I V E M A R K

N/A

N/A

54

5 1 1 4 4 4 2

55

SERVICE 1 DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 2 DATE

ENGINEER NAME

COMPANY NAME

TEL No.


COMMENTS

SIGNATURE

SERVICE 3 DATE

ENGINEER NAME

COMPANY NAME

TEL No.


COMMENTS

SIGNATURE

SERVICE 4 DATE

ENGINEER NAME

COMPANY NAME

TEL No.


COMMENTS

SIGNATURE

SERVICE 5 DATE

ENGINEER NAME

COMPANY NAME

TEL No.


COMMENTS

SIGNATURE

SERVICE 6 DATE

ENGINEER NAME

COMPANY NAME

TEL No.


COMMENTS

SIGNATURE

SERVICE 7 DATE

ENGINEER NAME

COMPANY NAME

TEL No.


COMMENTS

SIGNATURE

SERVICE 8 DATE

ENGINEER NAME

COMPANY NAME

TEL No.


COMMENTS

SIGNATURE

SERVICE 9 DATE

ENGINEER NAME

COMPANY NAME

TEL No.


COMMENTS

SIGNATURE

SERVICE 10 DATE

ENGINEER NAME

COMPANY NAME

TEL No.


COMMENTS

SIGNATURE

SERVICE INTERVAL RECORDIt is recommended that your heating system is serviced regularly

and that you complete the appropriate Service Interval Record Below.

Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service

as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls

© Baxi Heating UK Ltd 2007 Comp No 5114442 - Iss 3 - 2/07

POTTERTONA Trading Div is ion of Baxi Heat ing UK LtdBrooks House, Coventry Road, Warwick. CV34 4LLAfter Sales Service 08706 017 017 Technical Enquiries 08706 049 049Website www.potterton.co.uke&oe

��

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.

925.071.1


User’s Guide andImportant Warranty Information

Promax SystemHE Plus Range

Please keep these instructions in a safe place.If you move house, please hand them over to the next occupier.


Natural Gas

Potterton Promax System 12 HE PlusG.C.No 41 591 90Potterton Promax System 15 HE PlusG.C.No 41 591 91Potterton Promax System 18 HE PlusG.C.No 41 591 92Potterton Promax System 24 HE PlusG.C.No 41 601 21Potterton Promax System 32 HE PlusG.C.No 41 591 93

© Baxi Heating UK Ltd 2007 All rights reserved. No part of this publication maybe reproduced or transmitted in any form or by any means, or stored in anyretrieval system of any nature (including in any database), in each case whetherelectronic, mechanical, recording or otherwise, without the prior writtenpermission of the copyright owner, except for permitted fair dealing underCopyrights, Designs and Patents Act 1988.

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

The Company Secretary, Baxi Heating UK Ltd, Pentagon House, Sir Frank Whittle Road, Derby, DE21 4XA.

Full acknowledgement of author and source must be given.

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

Baxi Heating UK Ltd is aBS-EN ISO 9001 Accredited Company

The code of practice for the installation,commissioning & servicing of central

heating systems.

“Potterton” supports

1.0 Quick Reference Guide 3

2.0 Troubleshooting 4

3.0 Repressurising System 6

4.0 Clearances 7

5.0 Care of the Boiler 8

6.0 Legislation 9

7.0 Notes 10

8.0 Emergency 11

9.0 Warranty & Service 12

Section Page

Contents

Boiler Controls - see opposite pagefor Operating Quick Reference Guide

�

This product has an energy rating (A) on a scale of A to G.For more information see www.boilers.org.uk. This is a certification mark.

1.0 Quick Reference Guide

3© Baxi Heating UK Ltd 2007

Reset

bar

0

1

2

3

4

Reset

bar

0

1

2

3

4

ON/OFF/ResetSelector Switch

Display Central HeatingTemperature Control

Calibration Control System Pressure Gauge

OFF PositionThe boiler will not operate.

Central Heating Temperature ControlTurn the knob clockwise to increase or anticlockwise to decrease the temperature. Range 25 - 80° C.

Calibration ControlThis control is for use only by the installer or service engineer.

Central Heating Indicator - The indicator will illuminate when the boiler is in the centralheating mode.

Burner On Indicator - The indicator will illuminate when the burner has fired and is heatingyour central heating or domestic hot water.

Boiler Output Temperature - In either the central heating or domestic hot water positionthe display will illuminate showing the current boiler temperature in degrees centigrade.

Central Heating System Pressure - The normal operating water pressure is between 1 and2.0 bar. If the pressure exceeds 3 bar the safety pressure valve will operate and a fault isindicated. Contact your Installer.

Reset Reset

Central Heating & Hot WaterBoth Heating & Hot Water will operate.

ResetHold for approx 5 seconds and release.

Display

2.0 Troubleshooting


START

Make sure the gas supply isturned ON and check if othergas appliances are operating(e.g. fire, cooker).

If no gas, consult yoursupplier.

Is the ON/OFF/ResetSelect Switch in the( ) position andthe display lit ?

Is the ( ) light on and the( ) on ?

Check electricity to theboiler is switched on.

Reset

Display

Central HeatingIndicator

Burner OnIndicator

Boiler operating satisfactorily.

bar

0

1

2

3

4

Is the Central Heating SystemPressure needle in the GREENsection, between 1 and 2.5 bar ?

If the reading falls below 1 barrepressurise the system asdescribed in section 3.1.

Does the display show an errorcode e.g. E133, E110 ?

Boiler not working

NO

NO

YES YES

YES

NO

Turn the ON/OFF/ResetSelector Switch to Reset.

Reset

Error Code E119 showing lowpressure.

NO

YES

YES

NO

If boiler does notReset

2.0 Troubleshooting


Is the Timer ON and calling forheat ?

Ensure timer is set for CentralHeating ON (see anyinstructions supplied withtimer).

Is the Room Thermostat (iffitted) set high enough ?

1510

5

20

25

1510

5

20

25

Turn Room Thermostat tomaximum setting (typicalexample shown).

If you don’t know what you need to do toget the boiler to light, or need help withthe system and controls, contact your

installer as soon as possible.

YES

NO

CONTACT YOURINSTALLER ORSERVICE ENGINEER.

YES

121

23

4

56

7

89

10

11

CH ON CH OFF

Typicalexamples ofexternal timer

NO

3.0 Repressurising System


bar

0

1

2

3

4

bar

0

1

2

3

4

Fig. 1

Fig. 2

Normal Pressure

RequiresRepressurising

bar

0

1

2

3

4

FaultFig. 3

3.1 Central Heating System Pressure

1. The normal operating water pressure is between 1and 2.5 bar (Fig. 1). If the pressure exceeds 3 bar thesafety pressure valve will operate and a fault is indicated.Contact your installer.

2. It may be necessary to repressurise the systemoccasionally (Fig. 2). A filling device (the filling loop) willbe fitted on the system.

3. If you are unsure of its position, or cannot identify it,consult the installer who fitted the boiler.

4. The filling loop consists of two taps and a separatemetal braided hose with connection fittings.

5. Only when repressurising should the hose beconnected between the two taps. Ensure that the nutson the pipe ends are tightened onto the taps.

6. Fully open one of the taps first, and then whilewatching the pressure gauge, carefully open the secondtap.

7. When the needle on the gauge is indicating 1 or moreturn both taps off.

8. Disconnect the metal braided hose from the taps (asmall amount of water may be present) and remove it.Keep the hose in a safe place for future use.

4.0 Clearances


Fig. 4

200mm Min

780mm

450mm

200mm Min(300mm Min if

using 80/125mmflueing system

5mm Min

5mm Min

450mm Min

For ServicingPurposes

In Operation

5mm Min4.1 For your Safety

1. This appliance must have been installed in accordancewith the manufacturer’s instructions and the regulationsin force.

2. Any modification that may interfere with the normaloperation of the appliance without express writtenpermission from the manufacturer or his agent couldinvalidate the appliance warranty. In GB this could alsoinfringe the Gas Safety (Installation and Use) Regulations.

3. Your boiler must not be operated without the casingcorrectly fitted.

4. Do not interfere with any sealed components on thisboiler.

5. Take note of any warning labels on your boiler.

6. Your boiler should have the following minimumclearances for Safety and Maintenance (Fig. 34):-

Top - 200mmBottom - 200mmLeft side - 5mmRight Side - 5mmFront - 5mm (In Operation)

- 450mm (For Servicing)

7. If your boiler is installed in a compartment, do not useit for storage purposes. Do not obstruct any purposeprovided ventilation openings.

8. Flammable materials must not be stored in closeproximity to your boiler.

9. Avoid skin contact when your boiler is in operation, assome surfaces may get hot e.g. pipework.

10. Ensure that the flue terminal, outside the house,does not become damaged or obstructed, particularlyby foliage.

11. It is important that the condensate drain system isnot blocked, modified or damaged in any way as thiswould affect the operation of your boiler. Your installershould have insulated any exposed pipework.

GB - Heating Industry definition meaning England, Scotland,Wales, Northern Ireland, Isle of Man and the Channel Isles

5.0 Care of the Boiler


5.1 Cleaning the Outer case

The painted panels should be wiped with a damp cloth andthen dried completely. DO NOT USE ABRASIVECLEANING AGENTS.

5.2 Protection & Precaution

1. The boiler incorporates an integral frost protection featurethat will operate when the selector switch is in the ( )position. If the boiler temperature falls below 5° C, then theboiler will operate until the water temperature has beenraised.

2. If a system frost thermostat has been fitted (your installerwill be able to advise you), then to operate correctly andprotect your system, the gas and electricity must be left on andthe appliance set in the central heating mode.

3. The boiler incorporates an integral pump protection featurewhich continually monitors the time since the pump lastoperated. To prevent seizure, the pump will operate forapproximately 1 minute if it has not run in the last 24 hours.

5.3 Fault Indication

1. If a fault occurs on the boiler an error code may be shownon the facia display (Fig. 5).

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

3. E20, E28, E50, E125 & E160 indicate faulty components.You should make a note of the displayed error code andcontact your installer or service engineer.

4. If E110 or E130 is displayed overheat of the primary wateror flue system has occurred. Turn the selector switch to thereset position and hold for at least 5 seconds. If the boilerdoes not relight, or the code is displayed regularly contact yourinstaller or service engineer.

5. E119 is displayed when the primary water pressure is lessthan 0.5 bar. After repressurising the system the boiler shouldoperate. Your installer will be able to advise you about themethod of repressurising. See page 6 for further details.

6. E133 indicates that the gas supply has been interrupted,ignition has failed or the flame has not been detected. Ensurethat the gas supply has not been turned off, and turn theselector switch to the reset position and hold for at least 5seconds. If the boiler does not relight, or the code is displayedregularly contact your installer or service engineer.

Central Heating NTC FaultFlue NTC FaultHot Water NTC Fault Safety Thermostat OperatedWater Pressure Switch Not OperatedCirculation Fault (Primary Circuit)Flue NTC OperatedInterruption Of Gas Supply or Flame FailureFan or Fan Wiring Fault

E20E28E50E110E119E125E130E133E160

Table of Error Codes

Reset

bar

0

1

2

3

4

Display

Then

Fig. 5

6.0 Legislation


6.1 Installation, Commissioning, Service & Repair

1. This appliance must be install in accordance with themanufacturer’s instructions and the regulations in force.Read the instructions fully before installing or using theappliance.

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

3. Definition of competence: A person who works for aCORGI registered company and holding current certificatesin the relevant ACS modules, is deemed competent.

4. IN IE (Eire), this must be carried out by a competentperson as stated in I.S. 813 “Domestic Gas Installations”.

All CORGI registered installers carry a CORGI identificationcard (see Fig. 6) and have a registration number. You cancheck your installer is registered by telephoning 08704012300 or writing to:-

1 Elmwood,Chineham Business Park,Crockford Lane,Basingstoke. RG24 8WG.

or check online at www.corgi-gas-safety.com

The boiler meets the requirements of Statutory Instrument“The Boiler (Efficiency) Regulations 1993 No 3083” and isdeemed to meet the requirements of Directive 92/42/EECon the energy efficiency requirements for new hot waterboilers fired with liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by:Notified Body 0085.

Product/Production certified by:Notified Body 0085.

For GB/IE only.

6.2 Benchmark Commissioning Checklist

1. Please ensure that your installer hands you the boilerInstallation & Service Instructions with the “BenchmarkCommissioning Checklist sections completed. The detailsin the Checklist will be required in the event of anywarranty work. Keep the instructions in a safe place andensure that the Service Interval Record at the back iscompleted at each service visit.

RegisteredGas Installer

CARD SERIAL NO. 999999999

NAME:

A.N.InstallerCOMPANY:

Newtown Heating

EXPIRES: 31 DECEMBER 2010

PH

OTO

GR

AP

H

To confirm validity of this card please contact

CORGI on 0870 401 2300www.corgi-group.com

CORGI

00000

Fig. 6 CORGI Registration Card

7.0 Notes


8.0 Emergency


If you smell gas

Turn off the gas supply at the meter and call your gassupplier immediately. It is possible to isolate the boiler andat the isolating valve (Fig. 8).

In GB, Transco operate a 24 hour emergency service andthe telephone number will be listed in your telephonedirectory.

Faulty boiler

If it is known or suspected that a fault exists on the boiler, it must not be used until the fault has been corrected by a competent person.

Warning !

Gas Tap

Heating Flow, HeatingReturn and Mains Water

Inlet Isolating Valves

Fig. 7

Fig. 8

In an Emergency

If a water or gas leak occurs or is suspected, the boiler canbe isolated at the inlet valves as follows;

1. Turn off the electrical supply and turn the selectorswitch on the facia to the OFF position.

2. Using a suitable open ended spanner or screwdriverturn the square on the gas tap to the left to isolate the gassupply at the boiler (Fig. 7).

3. The isolating valves are positioned under the boiler andcan be closed by turning their taps to the right towardsthe wall (Fig. 8).

4. Call your Installer or Service Engineer as soon aspossible.

9.0 Warranty & Service


POTTERTONA Trading Div is ion of Baxi Heat ing UK LtdBrooks House, Coventry Road, Warwick. CV34 4LLAfter Sales Service 08706 017 017 Technical Enquiries 08706 049 049Website www.potterton.co.uke&oe

��

Comp No 5114441 - Iss 2 - 2/07

Information Label

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.

Serial Number

Date of Installation

Installer Details (name, address and contact number(s))

Please complete the boxes below

D D M Y YM

Standard Warranty Term & Conditions

12 Months Free Warranty - register todayTo receive your 12 months free warranty please complete the form suppliedwith the boiler or simply call heateam, the service of Baxi Heating UK Ltd on 08706 000 653.

Our promise to youIf you experience a fault with your new boiler, we aim to provide a safe andhigh quality repair service supported by our dedicated national network ofhighly skilled engineers. If your installer can’t resolve the problem for you, wewill do everything we can to get an engineer out to you as quickly as possible.Nothing in this warranty will affect your statutory consumer rights.

What you need to do if you experience a problem with your heating systemor the operation of the boilerYou should always contact your installer first, because the fault may not berelated to the boiler. If your installer confirms that the fault is within the boilerit self and he/she can’t repair it, our friendly customer service team is on handto help. Simply call our service division heateam on 08706 017 017 to book anengineer visit or for any general advice that you may need. Our contact centreis open Monday to Friday 8am - 6pm, weekends and Bank Holidays 8.30am -2pm, excluding Christmas Day and New Years Day.

When calling heateam it would be helpful if you could have the followinginformation to hand:-

1 boiler serial number (see opposite).2 boiler make and model number.3 Your installer name and address details.4 Proof of purchase (if you do not have the boiler serial number).

What this warranty coversFree of charge repair or replacement of components found to be faulty frommanufacture.

Free of charge replacement of the complete unit provided always that thefailure is related to a manufacturing fault that cannot be repaired or isuneconomic to repair.

The warranty runs for 12 months from the date your product is installed.

What this warranty does not coverRepairs to boilers which haven’t been installed and commissioned properly,and as set out in the installation instructions (this includes the need to flush thesystem effectively and add a suitable corrosion inhibitor).

Any damage caused by hard water scale deposits and/or aggressive waterresulting from corrosion.

Any other defects or failures, either in the connected heating system oroutside of the boiler itself.

Faults caused by inadequate supply of electricity, gas or water to the property.

Installations within commercial settings for which this boiler was not designed.

Reimbursement of any third party repair or replacement costs that we haven’tbeen told about or agreed with you in advance.

Compensation for consequential losses (e.g. loss of earnings, business losses,stress and inconvenience) arising from a production breakdown, includingrepair delays caused by factors outside our reasonable control.

Annual ServiceTo ensure you receive the maximum efficiency from your boiler werecommend your boiler has an annual service so you and your family cancontinue to enjoy heating and hot water comfort. To arrange an annual servicefrom one of our Baxi Heating UK Ltd heating experts, please call to arrange avisit convenient to you.

925.072.1

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